4 layers of glued cardboard, with the cardboard “grain” oriented at 90 deg. angles to one another. Easy open lid. Some pieces of reinforcement wood in select internal and external locations. Some duct tape. Internal and external straps. A few coats of wood lacquer on the outside for water resistance. Dolly wheels on one outside edge and a removable tow strap to pull easily thru airports. And a lot of time. A lot. 
Wow, thanks. Alas, I am in Atlanta. That looks like it could withstand a zombie apocalypse.
I have flown quite a bit including overseas. My biggest challenge by far is TSA. I don’t know how to solve the challenge which is their opening and removing many items and sometimes not putting them back in the case! Imaging arriving in Iceland 24 hours of Rift Iceland only to find a stem faceplate and bolts missing.
I have only traveled with Bike Box ii. Road, Gravel and M tt bike. Never any real damage. But often a ton of parts just thrown back in that were removed for inspection.
So perhaps the best solution is a case that requires the lease disassembly and the most visibility. Which means less inspection or movement of loose parts.
But then the challenge becomes size or case and over 50 pounds costs. And size of rental car. I often rent a minivan when traveling with bikes. Its not cheap!
The Evoc Road Bike Bag Pro is a cool case in theory, but it has no durability. And even worse, the company doesn’t stand behind its product when it breaks. After only a few uses, the hard shell part broke and part of the zipper broke making it near impossible to zip. Customer service told me to get lost.
I ended up renting an Evoc Road Bike Pro for my trip. (It is the version that fits with cockpit on, versus the Bike Bag Pro variant that requires more breakdown.) It worked great, and seemed pretty tough and likely durable unless it was grossly mishandled by the baggage handlers.
I read that Evoc has a newer version than what I used that is designed to be more durable with a fully polycarbonate base to protect the metal bike frame bars plus a better caster wheel. No clue if true, but they do seem to have adapted the case somewhat since the original version.
They have absolutely updated the case, but the updates seem to be pretty marginal. Time will tell if the new version holds up better, but it seems pretty insignificant from that standpoint, although the new casters are certainly better.
I have both the old case and the new one. Changes are minimal for sure. There’s some bumpers added to leading edges on the top plastic parts which seems like a decent improvement. The plastic in the older case felt thin and almost brittle in this area and mine did indeed crack. I plastic welded it and added some additional strengthening inside and have used it a lot since with no issue.
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I’ve flown several times with my size XS TT bike in a Premierbike hardcase, a last-gen one, meaning that the holes in the case to run the wheel skewers to anchor them through the case exterior are quick-release, so my newer thru-axles are too thick to work that way.
It still works completely fine with zero skewers anchoring the wheels, as the case has wheel-shaped cutouts for 3 wheels. Even with my XS TT bike with short-reach aerobars, I have to loosen the aerobar bolts to shorten them about 2 inches to fit in the case, I suspect this could be a pain if your TT bike has an integrated cockpit where the aerobars are difficult to retract or til completely downwards after loosening some screws. I also have to remove my seat (which is already at the lowest seat height possible) to fit into the case despite my bike being XS. So I guess the Premierbike case isn’t quite as massive as it initially seems.
Works great though, zero damage to my bike. The last time I flew with it I didn’t bother to really do extra frame protection and just relied on the foam blankets built into the case, zero issues. I did remove the RD, but I’m not sure I have to do that either, I just do it because every says to. I might risk not doing that in the future though, would save some time reinstalling it and packing it.
With this case, TT bike + 2 wheels is heavy enough that I have to remove the seat+seatpost and put in my other luggage to get the weight to 48.5 pounds. I tried flying it with the seatpost in the box at 51.0 pounds, but the flight attendant dinged it, and I had to move it on the spot to my lighter luggage or pay a $150 overweight fee.
I have one of these in my garage it lays on
If you put one of these in your kitchen maybe it can double as a hanging pot rack…
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I have all my Evoc bags stashed in a storage unit. They are awkward to store anywhere, but I may have a different problem since I have 4 bags…
If anyone is curious, the Evoc Bike Bag Storage Bag is surprisingly nice and worth the money for storage.