Chessington UK-based digital audio mixing console manufacturer DiGiCo has chosen 5 Star Cases to manufacture an innovative flightcase solution for its recently launched SD7 console.

The initial discussions to develop the case took place at the PLASA 2007 show in September, where the SD7 was previewed for the first time as a ‘concept' console. This has soon become a full production model, true to DiGiCo's rapid response ethos.

Based around the popular industry ‘Nosecone' type flightcase, 5 Star worked closely with DiGiCo's Chris Ladbrook, who heads the company's Mechanical Design team, to develop a case to meet the additional demands of this high specification console.

As with DiGiCo's D5 and D1 desks, the SD7 features ‘hot-swap' power supply modules and a main processing engine, which slide out at low level from the rear of the unit.

This requires the case to incorporate a hinged access flap so both these units can be quickly and easily removed. The console is supported by CNC machined plywood blocks, contoured to match its rear profile while mounted against load bearing sections of the chassis and the case.

DiGiCo SD7 branding was also machined into these supports before being texture coated.

Another DiGiCo requirement was for audio engineers to be able to fit additional temporary TFT displays to compliment the consoles' own three touch-screens. 5 Star's design team came up with a simple solution of incorporating a mounting ‘socket' with a captive bolt to accept a VESA wishbone arm. These ‘sockets' are supplied close to the rear supports on both sides of the case. One or both VESA mounts can be quickly screwed into these fixing points, giving the engineer additional flexibility to add screens.

On the base of the flightcase are four flush-fitting turned aluminium ‘top hats' to enable foldable tables to locate securely, giving a stable working platform for the case and console.

Full 2D and 3D CAD drawings of the proposed designs were exchanged between the two companies who both use similar systems.

"We wanted a flight case that took on the no-compromise design concept used on the SD7 project. Working through the process with 5 Star, it was clear that they value attention to detail as much as we do. It's a great case for an awesome console," says DiGiCo's managing director James Gordon.