Wilwood Calipers are manufactured from specific and proprietary aluminum alloys. Calipers may be forged from premium grade alloy billets, machined from blank billets, or formed using close tolerance casting processes. The manufacturing process for any given caliper is based on style, shape, size, volume, and the intended application of the finished product.

Many caliper models are offered with a choice of piston sizes, construction and material. Combined piston area, not caliper size, is the primary influence on a caliper's clamping power. The piston volume must match the master cylinder bore size and pedal leverage to realize peak performance from the system. Rotor diameter will also impact the system's effectiveness. Different piston sizes provide the car builder with options to maximize the overall balance and brake system performance.