HSL uses 5 Star exclusively to supply its flight cases. Rupert Reynolds, head of HSL rigging says: "The cases are extremely well built and 5 Star always turn them around quickly and efficiently - as they are frequently needed at short notice. They are also great at coming up with ideas of how to case the odder and more idiosyncratic pieces of kit!"
HSL's new hoist cases feature a customized removable and interchangeable inner cradle (a fixed one is found in all standard motor cases) to accommodate the three types of motors that they wanted to house in the trunks. 5 Star designed and built three variations of these special inner cradles to fit a choice of three different motor types.
The cases are colour coded to denote the type of hoists they contain, and house a variety of 1 tonne, half tonne or quarter tonne units, with two quarter tonne motors fitting into one case. The external dimensions are identical for stacking, storage and truck packing. The cases were CNC machined at 5 Star's Wisbech factory from various thicknesses of birch plywood. Additional timber supports are included to ensure maximum 'hold' retention for the heavy motors and chains. These removable cradles are one of many variations of chain hoist trunk available from 5 Star.
The design has recently been streamlined due to investment of CNC machining facilities at 5 Star's HQ. A second Thermwood CNC machining centre, complete with automatic 12 position tool-changer and high flow vacuum hold down was installed in the Autumn of 2005, and is now working alongside the existing CNC facilities.
The interchangeable inner cradles also benefited from 5 Star's recently installed new 3D software system - Solid Edge. This is currently being 'rolled out' to the production, design and quotations departments, having been specially developed over the last 12 months by 5 Star's technical team. All case hardware, types and templates are now designed into Solid Edge, giving the designer full 3D modeling and rendered images as well as CNC-ready geometry.
HSL was one the first 5 Star clients to see the benefit of Solid Edge, which was used to model the design for a twin Robe ColorSpot 1200 moving light trunk. HSL ordered 167 of these last year, many of which were used to transport their brand new luminaires to the 2005 Eurovision Song Contest in Kiev.
HSL's newest cases went straight out on ITV1's popular Dancing on Ice TV show, being recorded at Elstree Studios, for which HSL is supplying lighting and rigging. The show is using eighty one tonne hoists and 17 quarter tonne units, all of which arrived in their new cases.
(Chris Henry)
