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Case Study: Pioneer DJ Takes Flight with Trifibre

Pioneer DJ approached Trifibre to design and manufacture custom flight cases to protect valuable equipment during international transportation.

Pioneer DJ is a global supplier of professional DJ equipment and accessories, with a UK team based in London.

The main requirement of the project was to ensure that the flight cases were designed and built to a high standard to keep the gear inside safely protected on every journey. The cases also needed to be easy to manoeuvre and easy to load and unload within in a busy work environment.

Choosing an experienced manufacturer that uses only high quality materials is essential when looking for reliable and robust flight cases, as the implications of using poorly built flight cases include rapid wear and tear and misshapen foam inserts, which can potentially lead to damaged equipment during storage and transit.

Pioneer DJ arranged a meeting with one of our technical representatives to discuss their requirements.

Jack Canham, Product Planning Executive at Pioneer DJ, comments: “When reviewing other suppliers, they were not up to the build quality of Trifibre and also, they could not offer some of the features that we requested. It was the professional look and build quality that gave us the confidence to choose Trifibre for the job.”

The equipment required

Based on Pioneer DJ’s full list of requirements, the Trifibre team recommended waterproof injection moulded cases from MAX, with custom foam engineered inserts to be made using our state-of-the-art CNC foam cutting machinery.

Foam inserts were custom designed in numerous size configurations to accommodate the various makes and models of mixers and turntables supplied by Pioneer DJ, as the modular foam cases needed to fully support the equipment and ensure minimal movement during transit.

Great accuracy was needed to meet these requirements and our innovative CAD/CAM software enabled us to produce the designs with confidence and precision.

Pioneer DJ were impressed by the MAX injection moulded cases recommended by the Trifibre team. Their previous supplier had provided low quality cases that provided only minimal support and no waterproofing, greatly increasing the risk of damage to the equipment.

As a UK distributor for MAX cases, we recommend them for a range of applications as they are IP67 certified to protect against dust and water, providing tough, durable and reliable protection, even in the most extreme conditions.

Pioneer DJ provided our team with access to actual equipment, which we were able to accurately measure at the Trifibre Design office to ensure absolute precision in the final products.

The manufacturing process

After initial drawings were produced, two foam design samples were presented for evaluation and approval by the Pioneer DJ team, both in the UK and its headquarters in Japan.

We recommended branding be added to the exterior of the MAX cases to provide a sleek and professional finish, so screen printing of the logo was completed on all case lids and barcode labels.

The design drawings and machine foam samples took approximately one to two weeks to produce, while the full production run took four to five weeks to complete, after final approval.

The approval process by Pioneer DJ UK and Japan took the longest amount of time, as the team wanted to ensure they had the right product to suit their needs, using additional evaluation from resellers for vital feedback on the final products. However, this ensured a product that was exactly right from the outset, just as it should be.

The completed shipment of IP67-rated injection moulded cases with custom foam inserts were delivered in full and on time to Pioneer DJ’s European hub. A full description of the case, complete with the model numbers of the equipment each case accommodates, were attached to the cardboard shipping cartons. This made for easy identification and distribution by Pioneer DJ and its global resellers.

The design, evaluation and manufacturing process was repeated for each product range.

The result

The solution developed by Trifibre will only be available in Europe to Pioneer DJ’s authorised dealers and retailers, instore and online. Products supplied by Pioneer DJ require specialised cases to provide reliable, durable protection for high-value equipment during transit and storage.

Its products are utilised by many companies from all over Europe, which rent out DJ equipment for festivals and concerts, and require professionally branded cases for additional reassurance that equipment will be safely protected.

Jack adds: “Nash, our main contact at Trifibre, was very helpful and understood our needs and what we wanted to achieve for the flight cases. He was quick to respond to any issues or questions we had and was great to work with.”

Find out more about our custom foam inserts or shop our off-the-shelf range of MAX cases.