Interiors

Endless possibilities

We offer virtually endless possibilities when it comes to interior design. As a custom manufacturer, we do not limit ourselves, or our customers, to a standard set of rules regarding interior treatments. We will make your concept a reality with the support of our skilled staff of case designers and interior fabricators, some with over 30 years of experience. Many types of foam are available to ensure the proper protection of your valuable equipment. The most common types of foam used in Calzone/Anvil^® cases are described below. Please contact us for any special foam requirements.

Foam Fabrication

At Calzone/Anvil, we take foam very seriously; it’s the closest layer of protection around your instruments. And for years, we’ve treated foam selection and placement as a science, not an afterthought. Many case companies cut corners with insertable pre-cut foam sections, resulting in a case that somewhat protects your investment. Because we are custom case manufacturers, every piece of foam in your case is custom designed for a specific purpose, and your instrument fits exactly.

We have many standard designs available, but whatever your needs, our interior fabrication design team is at your disposal. The most common types of foam used in Anvil Cases and Calzone Cases are Estafoam (polyester), Ethafoam (polyethylene) and Anti-Static. For many years a standard in case design, Estafoam is typically supplied in 2.0 PCF and 3.8 PCF. PCF (pounds per cubic foot) for the 2.0 means that a 12″ cube weighing two pounds would require 50-65 pounds of pressure to depress a 4″ thick block 1″, while the 3.8 PCF requires 60-80 pounds. Ethafoam offers a closed cell design that delivers lighter weight, a pleasing appearance, superior durability and chemical resistance. However, Ethafoam is combustable and should not be exposed to flame. Many times a combination of Etha and Esther foams are used in popular case designs. Finally, our special Anti-Static foams are designed to protect against static discharge. Our Anti-Static Polyethylene extracts static charge from an item and dissipates the charge off the surface of the foam by use of a Surfactant (a chemical applied to foam at time of manufacturing). Our Anti-Static Polyurethane is conductive carbon filled, designed to extract a static charge and conduct away from the contents.

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Anti-static Foam

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Polyester/Ethafoam Combination

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Ethafoam

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Ester Foam

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Carpeted Interior

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Plush Velvet

Polyester Foam Specifications

2.0 PCF (pounds per cubic foot) – a cubic foot density as follows: a 12” cube weighs 2 pounds – it requires 50-65 pounds to depress a 4” thick block 1”

3.8 PCF (pounds per cubic foot) – a cubic foot density as follows: a 12” cube weighs 3.8 pounds – it requires 60-80 pounds to depress a 4” thick block 1”

Ethafoam (Polyethylene) Specifications

The advantages of Ethafoam are: pleasing appearance; light weight, flexible; closed cell (water absorption and water vapor transmission rates are very low); tough; durable; chemical resistant (exceptionally resistant to most solvents and other chemicals at room temp – acids and alkalis normally have no effect); resilient (resists multiple impacts); excellent recovery from shock or strain; and returns to shape quickly after impact. Note that Ethafoam is combustible and should not be expose to flame.

Anti-Static Foam Specifications

Anti-Static Foam protects against static discharge. There are two types: Polyethylene – anti static designed to extract static charge from an item and dissipate charge off surface of foam by use of a Surfactant (a chemical applied to foam at time of manufacturing); and Polyurethane – conductive carbon filled, designed to extract static charge and conduct away from item.

References

ASTMD-1596 – Standard test method for shock absorbing characteristics of Package Cushioning Materials; Federal specifications PPP-C-1752B – Cushioning Material, Packaging, Unicellular Polyethylene foam Flexible; Mil-HDBK-304B – Military Standardization Handbook, Package Cushion Design