What is a custom fitting and why does it matter?

A custom fitting is a purpose-made adaptor or jig – a manufactured element in wood, plastic or metal that lets a standard component be mounted exactly right inside a unique construction. By custom-producing only the fittings, we can build most of a solution in well-known standard material. It saves time, reduces costs and makes production more predictable for every department involved.

Why do you do load calculations and how does it affect the delivery?

Load calculations are done for constructions that carry weight – suspended LED walls, stage risers, truss rigs and multi-level structures. The calculations ensure the construction handles the load with a safety margin, and they are used as a basis for venue approval and fire safety documentation. That gives the client confidence and us shorter approval processes.

Can you build prototypes and test solutions before production?

Yes. The product development department builds prototypes for new products and constructions – testing function, assembly and load capacity before we start full-scale production. This is particularly valuable for recurring products such as exhibition stand concepts and activation modules.

Can you produce custom components that aren't available off the shelf?

Yes. That is the core remit. We produce custom components in wood, metal, plastic and composite materials when the standard range does not cover the need. That ranges from a custom-shaped fixture housing to a bespoke cable routing system inside a stand build.

How does product development collaborate with carpentry and other departments?

Product development is the hub of complex productions. They take requirements from the light, video and sound departments and translate them into construction documentation for the carpentry shop. During the build, product development staff are on site to solve technical details as they arise and make sure every part fits together as planned.

Can you produce a full technical construction drawing?

Yes. The product development department produces detailed technical drawings in CAD with dimensions, tolerances and material specifications. The drawings are used as production documentation for the carpentry shop and as documentation for client approvals and regulatory requirements.

Can you help optimise an existing construction for lower cost?

Yes. We review existing constructions and production concepts with the aim of finding smart simplifications – without compromising function or aesthetics. It can mean replacing expensive custom material with a standard alternative, reducing the number of unique parts or improving the assembly order for a faster rig.

Triangled and Edgetron – EDGE Product Development

Product Development

EDGE's product development department has two functions. The first is to act as the technical binding agent between the construction departments – applying an engineering perspective to ensure that complex solutions are as safe, sustainable and efficient as possible. The second is to develop new product ranges that address needs arising in the field that the existing market does not adequately answer.

"We build what we design – and sometimes we design what no one else builds. The product development department ensures that every solution holds together technically, structurally and economically, from drawing to delivery."

Technical integration and construction validation

When EDGE produces advanced stage and installation solutions, the product development department coordinates the technical details between departments. This can involve confirming that cable penetrations for power and signal are in the correct position in the carpentry production, that LED panels have the right mounting points, or that custom-machined jigs in wood, plastic and metal mean the majority of a solution can be built from standard materials – with only the elements that genuinely need to be unique being specially produced.

This approach is economically and logistically important: standard materials are familiar to all departments, quick to handle and straightforward to replace if needed. Special production is reserved for the parts of the solution where it actually makes a difference. The department also calculates the structural integrity of constructions – both to ensure safety and to avoid using more or heavier material than necessary. Accurate structural calculations reduce transport volumes and weight, which in turn contributes to more sustainable transport and a lower CO₂ footprint.

Proprietary product ranges

The second function is developing product ranges that address needs arising in the field which the existing market does not adequately answer. Products developed by the department include:

Triangled – triangular stage fixture

Triangled is a triangular stage lighting fixture with a unique design that enables set designs only EDGE can produce. The system includes the fixture, a dedicated control system and a complete road case solution for transport and reuse.

Edgetron – scalable LED fixture for large-scale set designs

Edgetron is inspired by the Martin VDO Sceptron but is a simplified variant manufactured by EDGE in lengths of 1 m, 2 m and 3 m. Having three standard lengths makes it possible to build large-scale set designs with high light output in a very cost-effective way. The system includes the fixture, control system, a complete transport solution and a wide range of rigging accessories for different mounting situations.

LED wall ground support rigging system

Existing systems for rigging LED walls from ground level are built for large festival and concert stages – they are bulky, heavy and poorly suited to the high finish requirements of conference and event venues. EDGE's product development department created its own system: compact but strong and safe, with rigging beams in steel and aluminium, concrete feet for stable anchoring, and integrated step brackets and rungs on the rear of the structure so technicians can safely reach the full back of the screen for cabling and maintenance.

The result: rigging time for LED walls reduced by over 50%, and transport volumes by approximately 20%. A solution that saves both time and resources on every production.

Rigging and mounting details for sound, lighting and video

Beyond the three product ranges above, the department has developed countless custom details and tailored mounting solutions for sound, lighting and video – smart jigs, adapters and bracket solutions that allow standard equipment to be mounted faster, more safely and with a better finish.

Frequently asked questions about product development

What does the product development department do in a typical project?

In complex projects, the department acts as the technical binding agent between the construction departments. They coordinate cable penetrations, mounting points and custom details between carpentry, lighting, video and sound to ensure the overall solution holds together technically – without unnecessary compromises or time-consuming improvisation on site during the build.

What is a custom jig and why does it matter?

A custom jig is a precision-machined fitting – an element in wood, plastic or metal that allows a standard component to be mounted in exactly the right position within a unique construction. By specially producing only the jigs, we can build the majority of a solution from familiar standard materials. This saves time, reduces costs and makes production more predictable for all departments involved.

Why do you carry out structural calculations and how does it affect the delivery?

Structural calculations serve two purposes: safety – ensuring no construction fails during an event – and material optimisation. By calculating what a structure actually needs to withstand, we use the right dimensions and the right material weight, avoiding unnecessary over-engineering. This reduces transport volumes and weight and, in turn, the CO₂ footprint of each production.

What is Triangled and what makes it different from conventional fixtures?

Triangled is an EDGE-manufactured triangular LED stage fixture. Its triangular form creates unique geometric lighting effects and set designs that cannot be achieved with conventional rectangular fixtures. The system is complete with a control system and road cases, and is produced entirely in-house at EDGE – giving full control over specification, quality and stock availability.

What is Edgetron and why does it come in three lengths?

Edgetron is an EDGE-manufactured LED bar fixture inspired by the Martin VDO Sceptron but designed for cost-effective large-scale set design. The three lengths – 1 m, 2 m and 3 m – can be combined freely to cover exactly the surface area required without needing to custom-manufacture a new fixture for each project. The system is delivered with a control system, transport solution and a wide range of rigging accessories.

How does EDGE's LED wall ground support system work and why is it better?

The system consists of rigging beams in steel and aluminium, concrete feet for stable anchoring, and integrated step brackets and rungs on the rear – so technicians can safely reach the full back of the screen for cabling and maintenance. It is designed for the high finish requirements of conference and event venues, not outdoor festivals. The result is a rigging time reduction of over 50% and a transport volume reduction of approximately 20%.

Can you develop a custom solution for a specific project?

Yes. In addition to the established product ranges, the department continuously develops custom details and tailored solutions for specific projects. If a project requires a unique mounting solution, a custom rigging bracket or a jig for an unusual combination of components – that is precisely what the product development department is for.

How does the product development department contribute to EDGE's sustainability work?

In three ways. Structural calculations optimise material use and eliminate unnecessary weight. The jig concept keeps the proportion of specially manufactured material low in favour of lightweight standard materials. And proprietary products such as the LED wall ground support system reduce transport volumes by up to 20% compared to conventional alternatives. Together, this delivers fewer and lighter transports per production.

Product development – proprietary solutions and technical construction validation