A thermal cart for in-flight distribution of consumables. An enclosure is formed by thermally insulating material, including a first side panel, a second side panel, a top panel, a bottom panel, at least one door frame, and a door in each at least one door frame. A rear panel is provided in half-size carts where only one door frame and door are provided. Full size carts ae provided where a rear door frame and rear door are provided instead of a rear panel as used in the half-size cart. The thermally insulating material may include a thermoplastic inner lining, at least one vacuum insulated panel, and an outer structural panel. A plurality of rods is provided, each having end of rod tooling. Complementary tooled structures such as binding barrels, or sleeves, or threaded holes, are provided for joining with ends of the rods. Joints may be provided and secured to locate and provide resistance for securing the rods in tension. Frame assembly extrusions may join adjacent panels, and an inner elastomeric extrusion is provided with each frame assembly extrusion, to provide a seal with the thermoplastic inner lining.