5 Star Cases : Foam Inserts : Racks : Consoles : Trunks : Custom Build


	5 Star Cases Limited is pleased to announce that it will be taking part in the Farnborough Airshow 2010. This huge exhibition takes place every other year and in 2008, saw over US$88 billion worth of business generated during the event.

	FIA is a trade only exhibition, running from 19th to 23rd July. However, Public Day and air show is over the weekend of 24th and 25th. Over 150,000 visitors are expected over the weekend alone!


	5 Star will be displaying a wide variety of specialist cases for many applications and industry sectors, including aerospace, military, engineering and more.


	5 Star are now able to offer a unique service to compliment it’s range of custom built cases and foam inserts. We can now produce high quality Polyurethane (PU) Moulded Inserts for a wide variety of applications.


	Specialist PU mixing equipment is utilised to produce synthetic inserts and mouldings. PU foam is made by mixing two liquid components under shear and pouring or injecting them into a mould cavity. The chemical reaction kicks off within seconds and carbon dioxide gas is given off as bubbles.

As the polymer is formed the bubbles are trapped in the matrix forming a foam.The constituents can be modified to form foam with many different densities and properties. Pigments or dyes can be added to one of the components, or injected at the mixing stage so you can have any colour you want. The pressures involved in this type of moulding are considerably less than injection Moulded inserts. Therefore, less complex mould tooling can be produced. Typically, once poured the insert can be removed within minutes (depending on the size of the finished article).
Our team of designers can produce specialist tooling data from Solid Edge v20. This data can then be sent to the tool-maker to produce the mould tooling. Usually this is produced from aluminium stock, but can be from resin or even plywood. Plywwod is by far the cheapest but surface quality is much reduced and the life of the tooling will be relatively short.

These PU inserts are produced at a facility in China, as well as the mould tooling. However, we produce the 3D data for the tooling as well as renderings for proposed inserts at our UK factory. Usual lead-time from order is around 10 to 12 weeks to the UK.
One of the first items to be produced is the new Pioneer CDJ2000 insert, shown on the left.


	Also shown here is the mould tooling for the Pioneer CDJ2000 insert. Machined from aluminium, the tooling is in two main parts which is hinged to allow removal of the finished insert. The tooling is also highly polished to the visible faces of the insert to ensure a smooth finish.

	These PU inserts are particularly suited to...

		Moving Head Lighting Fixtures

		Mixing Console Support ‘Cheeks’

		Protective Bump Stops


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