Freefly VR Beyond & Extreme Fliers Flight-case


By Kiran Sagar


Freefly VR Beyond was launched at the end of last year, so we decided to develop a flight-case to display the new headset at exhibitions, shows and conferences. This idea came from the possibility of joining with Extreme Fliers, a Micro drone company that have shown a lot of interest in the Freefly VR Beyond. This would consist of a micro drone with a camera that can be controlled whilst using the Freefly to experience the drone's view. It is a great concept that takes the immersive experience of VR to a new level.

The initial concept of designing a flight-case for the two products came from us wanting to use it for the CES show in Las Vegas at the start of January. This meant the flight-case had to be designed and made in less that 48 hours, as it needed to be shipped of to Vegas in time for the show. Here's a short video of how we made it happen. 


Video Shot and edited by Hannaan Bhatti, Music: CABU & Akacia - Gold


Step-by-step production of Freefly VR Beyond & Extreme Fliers Flight-case:

  1. Parts are reverse engineered on Solidworks, using callipers to get accurate measurements and combine complicated shapes to simplify the design.
  2. Foam model is created in CAD by subtracting parts and offsetting surfaces to ensure there is clearance for each part to be removed easily.
  3. Block is split into 12mm thick layers ensuring there are no undercuts and complicated angles as these cannot be laser cut.
  4. Files are saved in DWG format, so they are suitable for laser cutting and can be translated into a 2-dimensional drawings.
  5. The black and orange Plasterzote foam is ordered, using the orange layer to be placed at the base of each gap to indicate when an object is being used or missing.
  6. All files are sent to Lasercut.London to be cut, where the drawings are checked and any changes made to make it suitable for laser cutting.
  7. The layout and graphics are designed for the vinyl sticker and then printed and cut to go on the outside of the case.
  8. Plasterzote layers are glued together using UHU glue and extra strength double sided tape. Making sure glue is applied to all edges and left to dry for a reasonable amount of time.
  9. Sticker is carefully applied to the outside of case using a smoothing tool to remove air bubbles and creases, obtaining a suitable surface finish. 

Final Flight-case











Overall this was a successful 48 hours from concept to final product, and the result was perfect to showcase our collaborative project with Extreme Fliers at CES 2017. We would like to thank Chris at Lasercut.London for cutting the foam and printing the vinyl stickers to help produce the flight case in such a short space of time. 


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