Custom Design

bespoke sofa flight case

From exhibition furniture to architectural models, mobile photo booths to sculptures, 5 Star has designed and manufactured custom flight cases for many different items and uses. Flight case requirements are as unique as anyone using them!

The uses and contents present a myriad of options, and one of the many areas in which 5 Star specialises is bespoke flight case projects. Having a custom flight case designed along with the associated custom protective foam inserts is often essential to meet a specific need.

custom design flight case

5 Star has designed bespoke flight cases for every imaginable object – and some that are not!! All you need to do is let us know the object needing to be cased together with your ideas … and our dedicated team will do the rest! Our design team uses the latest software, CAD technologies and number crunching programmes and spreadsheets for even the simplest of case designs.

With straightforward spreadsheet designs and quotations, customers receive a detailed drawing of the case showing both the external and internal layout .  A fully visual representation of the proposed flight case project illustrates how any compartments, dividers and basic foam layouts will work within the case environment – so you can see exactly how it will work on a practical level.

These spreadsheets also include the all-important BOM (Bill of Materials) used by the production team and stores department who pick the necessary hardware, fixings and other materials.

All of these build spreadsheets are archived with a unique reference number which can be recalled instantly for future ordering reference.

For the most specialist and complex custom flight case projects, our design team utilizes Solid Edge 3D software. This is a powerful state-of-the-art tool that has been heavily customised by 5 Star’s technical and design departments, and includes full 3D virtual parts and modelling of all the hardware, extrusion profiles, fixings etc. that are used in the construction of a case.  Almost every piece of hardware supplied to us has been accurately mapped by 5 Star for use in the Solid Edge software and in the process, building  a vast library of virtual hardware and an invaluable resource from which to select during the flight case design process.

Solid Edge design software is used only for special projects not all case designs.  5 Star reserve the right to select which projects are suitable for this service.

bespoke case

Show above is probably the most complex custom flight case ever designed and built at 5 Star.  Audiotonix Group company Calrec Audio tasked 5 Star with designing something to showcase a new product that was being launched at an expo in Las Vegas.  The only brief given to us was 'Crazy Golf'.  Having presented a concept, design and setup of the project with the marketing team at Calrec, 5 Star delivered the complete package in three weeks.

The basic setup consisted of four crazy-golf layouts, each in its own case section.  All of the sections had a relevant theme to Calrec and the new product launch.  These included a 'microphone forest', a broadcast truck, Calrec'c premises Nutclough Mill in Yorkshire and London's Tower Bridge (used on sister company DiGiCo's booth at the same expo).

The Mill, broadcast truck, Tower Bridge and yes....even the sheep were all designed, drawn, CNC-machined and hand-painted by 5 Star.  Motorised 'flying faders' were also constructed and installed by 5 Star's technical team, which were part of the crazy golf challenge.

Contact our sales team on 0845 5000 555 to obtain a design and quote for a custom flight case design.

In the gallery you can see different projects we’ve produced that can serve as a reference. Social media is also a great place to catch up with news and recent projects. Check 5 Star on FacebookLinkedInTwitter an Instagram

And below is just a very small but varied selection of some Custom Flight Cases that have been produced over the years.