Ply · Aluminium · Penn Elcom · Australian Made

Custom Road
Cases.

Heavy-duty cases for gear that tours. AV, IT, trade show rigs and anything else that has to travel and arrive working. Built in Melbourne with Penn Elcom hardware.

16U workstation rack case with both lids folded out into trestle tables, holding a mixing console and rack gear

Trusted by touring, AV, defence and engineering teams

Arts Centre MelbourneCFABenQGoogleHPMercedes BenzMotoGPSiemensMitsubishi Heavy IndustriesToshibaPwCThermo Fisher ScientificSKFOlympusGrass ValleyKiddeUniversity of South AustraliaRugby World CupSICKBalluffifm

Built to survive the road.

AV gear, IT equipment, a trade show rig, or something nobody has built before. We have built road cases in Bayswater since 2012, in off-the-shelf sizes or made to order in any shape and configuration. Every one starts from these four standards.

Need it lighter? Our custom flight cases use a reduced-weight build.

Compact road case with recessed spring handles, ball corners and castorsRecessed handles · Ball corners
Shell

HD Laminated Ply

A 10mm heavy-duty laminated plywood shell.

Options: Coloured laminates

Best for Heavy touring

Frame

Aluminium Angle

Heavy-duty aluminium angle on every corner, with tongue-in-groove angle on the lid openings to close the seam.

Options: Powder coating

Best for Rough transit

Fittings

Penn Elcom Hardware

Recessed lockable butterfly latches and recessed sprung handles, so nothing protrudes to catch or shear off in transit.

Best for AV and IT freight

Rolling

Wheels & Mobility

100mm Penn heavy-duty swivel castors, locking or braked.

Options: Built-in corner castors, Extendable handles

Best for Heavy rolling loads

Configure it around your gear.

Three decisions make the case: how it opens, what holds the gear inside, and what goes on the outside. In-house CNC and a full hardware catalogue mean large runs and complex foam designs are not a problem. Tell us what you need and where your budget sits, and we spec a case to match.

Road case with five drawers extended, each divided into labelled compartmentsDivided drawers · Labelled compartments
Interior Protection
High Density PE Foam
Closed-cell foam for rigid protection.
Open Cell Foam
Mid-density cushioning for delicate gear.
Convoluted Eggcrate
Lid foam that holds contents firm.
Heavy Duty Carpet
Hard-wearing lining for general use.
Foam Lined Dividers
Compartments for kits that share a case.
CNC Cut Inserts
Shadow-cut foam shaped to your exact kit.
Hardware & Extras
Lift-Out Drop Tray
A second layer that lifts clear of the base.
Straps & Tie-Downs
Anchor points for gear that shifts.
Stackable Cups & Feet
Castor cups and feet so cases stack square.
Overlatches
Join cases together for transit.
Trapdoors
Cable hatches and quick-access panels.
Ramped Lid
For side-loading models that roll in.
Label Holders
Tour plates and ID labelling.
Vinyl Wraps & Branding
Company graphics and coloured laminates.

Interiors are cut on the same CNC as our custom foam inserts.

Cases we've built.

252 documented builds, from one-off cases to production runs.

Browse all 252 projects
Project Spotlight
UniSAEducation

Custom Wardrobe Garment Road Cases

Wardrobe garment cases for UniSA. Folding front doors open to hard dividers and a carpet lined hanging space.

View Case Study
Off The Floor Recently

Custom Made Road Case With Laptop Dividers And Accessories Compartment

Giant Packer Case With Front Hinged Lid

PWC

Custom Pinboard Shelf Road Case

Need something like these? Send your gear list and we will spec the case.

Get a Quote

From the workshop

Custom builds from our Melbourne factory. Tap a photo to view it full size.

Specialist builds.

Jobs that need more than a box on wheels.

Custom Road Case Packer With Custom Drawer Inserts & Pelican Case With Custom Foam Inserts

Motorsport & Trailer Fitouts

Transporter fitouts, engine and running gear cases, and drawers with CNC foam tool inserts. Our cases sit in pit lanes from GT and Porsche championships to V8 Supercars.

See this job
Custom Signage Panel Road Case

Trade Show Fitouts

Pack a travelling show into cases and skip the palletising and repacking between events. Less to worry about with forklifts, security and weather.

See this job
Large Custom Road Case With Split Lid For Chandelier

Art & Exhibition Transport

Framed wall art cases, roll-in cases with ramps for larger works, and custom cut foam for anything awkward.

See this job
Custom Interactive Mounted Screen Road Case Unit

Marketing & Product Presentation

Cases built around the display, so product turns up organised and undamaged. Custom branding, signage and full vinyl wraps.

See this job

Tender Document Presentation

Melamine or upholstered fit-outs, CNC cut-outs for the presentation books, branded vinyl wraps and powder coated angle.

Something else?

Whatever the equipment or the industry, we work it out with you. If we haven't built something similar before, a new concept is never too hard.

Tell us about it

Getting a quote.

Send us three things. We spec the shell, foam, hardware and build format, then confirm price and lead time.

Your gear

A list of what goes in, with dimensions.

How it travels

Freight, touring or trade show, and how it needs to open.

How many, by when

One case or a run, and your deadline.

Four matching road cases with lids closed, staged in the yard before dispatchBuilt in Bayswater · Shipped Australia-wide

Frequently asked.

Lead times, branding, interiors: common questions before you commit.

What's the lead time on a custom road case?

Standard builds take 5 to 10 days. Large runs and complex fit-outs can take longer, so tell us your deadline up front and we'll confirm a date before you commit. Call (03) 9720 5300 or email sales@protectapack.com.au if you're working to a tour or show schedule.

Can you brand the cases?

Yes. Vinyl wraps and branding to match your company identity, plus coloured laminates, powder coated angle, signage, and label holders for asset tagging.

Do you build one-offs, or only production runs?

Both. A single case or a truckload is the same conversation. In-house CNC means large runs and complex foam designs aren't a problem, and dealing direct with the manufacturer keeps the budget in check.

How do I choose between a road case and a flight case?

Road cases use 10mm HD laminated ply, which is the heavier, more protective build for gear that tours hard. Our lightweight flight cases use a lighter construction where carry weight and airline handling matter more than maximum armour.

Can the interior be cut to fit my exact gear?

Yes. Interiors range from a simple high-density foam lining through to extra padding, foam lined dividers, and CNC cut inserts shaped to each item. Send us the gear list or the units themselves and we design the layout.

Ready to hit the road?

One case or a truckload, built in Melbourne around your gear.

  • Quote within 24 hours
  • Free, no-obligation
  • Australian made