REAL PROJECTS · INDUSTRIAL DESIGN AND MANUFACTURING

Products brought from idea to reality

Product development case studies

Discover how we turn ideas and requirements into physical products. One example is the plush kiwi with an internal GPS compartment that we developed and manufactured for an Air New Zealand promotion.

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FEATURED CASE STUDY · AIR NEW ZEALAND

A plush kiwi designed to interact with the city

For a promotional activity associated with the Rugby Championship and the All Blacks in Argentina, we developed and manufactured a plush kiwi housing a GPS device. A1Pack handled the physical character design, materials, internal access to the device and production with specialist workshops.

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01 · The challenge: an object for an experience

The Air New Zealand campaign, developed through an agency, required a recognisable, friendly and portable object for a promotional activity involving routes around Buenos Aires. The plush toy had to represent a kiwi and house a GPS device supplied by the agency.

  • Use context: an object designed to accompany participants on the move.
  • Manufacturing challenge: manufacture a distinctive animal shape that differed from conventional plush toys.
  • Integration requirement: incorporate an internal GPS compartment while retaining the character’s identity.

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02 · Textile design and materials

We investigated how to build the kiwi’s volume using fabric pieces, seams and stuffing. We worked with specialist suppliers to turn the design into patterns and solutions suited to plush toy manufacturing.

  • Form: defining the kiwi’s silhouette and proportions.
  • Textures: comparing smooth fabrics and different pile finishes to achieve the intended appearance.
  • Brand identity: developing a leather medallion engraved with the Air New Zealand brand.

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03 · Testing and prototyping

Before production, we made successive samples, first with smooth fabrics and then with pile fabrics, to assess the character’s expression and construction method.

  • Textile samples: comparing texture and finish options.
  • Construction: reviewing patterns, seam types and body assembly.
  • Device integration: developing the internal GPS compartment within the plush toy.

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04 · Manufacturing and delivery

Once the design was finalised, we coordinated plush toy production with specialist manufacturers and delivered the toys for the promotion. Our scope covered the physical object: design, prototypes, the textile GPS compartment, the leather medallion and manufacturing. The agency supplied the devices and managed the campaign.

  • Final design: a kiwi character with specified materials and construction.
  • Production: coordinated work with specialist plush toy manufacturers.
  • Outcome: plush toys manufactured and delivered for use in the promotion.

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More product development case studies

Explore other products developed by A1Pack, from initial prototypes through manufacturing.

From a unique object to a manufacturable solution

A custom product requires more than an attractive shape: it needs solutions for materials, joints, components, suppliers and production. At A1Pack, we integrate these decisions to turn an idea into a physical object.