Caissons Kyber (StarWars)

February 12, 2026 by

Federico Solutions, Myrko Federico

Kyber Crystal Container (Star Wars Death Star Collection)

Sector:Luxury Watchmaking / Collector

Period:March-April 2021 (intensive production ~2 months)

Client:Kross Studio (Geneva) — Watch brand under Disney/Star Wars license

Context

Kross Studio is a Geneva-based watch manufacturer that produces collectible watches under Disney and Marvel licenses. For their collectionDeath Star Central Tourbillon, they needed an exceptional collector's case: anauthentic reproduction of the Kyber crystal containersof the Galactic Empire (Star Wars), serving as a box for the watch, its straps, and a real Kyber crystal from the film.

Specifications:

Scale:1/2 of the original(1.20 meters long in the film → 60 cm long)
More than 700 piecesper container
Fully assembled and hand-painted
Immersive details true to the Star Wars universe

My role: produce all the black grooved plastic parts and the control panels of these containers ina very tight deadline(March-April 2021).

Problem

Major technical challenge:

Material:POM-C (Delrin)— high precision plastic engineering,1mm thickness(extremely thin and difficult to machine without deformation)
Complex geometries: organic shapes, fine details, interlocking parts (700+ parts per container)
Tight tolerances: all parts must fit together perfectly
Control panels: parts with text in Aurebesh alphabet (Star Wars), buttons and details in machined aluminum

Manufacturing challenge:

POM-C 1mm: material that lifts during CNC milling →part holding issue
Need to create a suitable clamping solution
High production volume: several containers to produce
Very short lead time: 2 months of intensive production

Equipment challenge:

The existing CNC could not properly hold the 1mm POM-C sheets
Solution to create: development and manufacturing of alarge format vacuum tablecustomized for the CNC

Solution

Technical innovation: large format vacuum table

In response to the POM-C 1mm holding issue, I designed and manufactured alarge format vacuum tablesuitable for my CNC:

Table design (porous surface, vacuum distribution channels)
Manufacturing and integration on the existing CNC
Testing and calibration
Result:perfect holding of 1mm POM-C sheets without deformation during machining

Production of parts

Materials:

Black POM-C (Delrin): structural parts, panels, details (1mm)
Aluminum: buttons, knobs, metal elements of control panels
Orange paint: characteristic finish of Empire containers

Produced parts:

Container structural panels (fronts, top, sides)
Control panels: panels with engraved Aurebesh text, indicators, machined aluminum buttons
Grills and decorative details
Junction and assembly elements
700+ parts per container, all CNC machined

Process:

Receiving design files (Kross Studio)
Preparing CNC programs (adapting to material constraints)
Manufacturing the vacuum table
Mass production of parts (POM-C + aluminum)
Quality control part by part
Delivery for assembly and final painting (Kross Studio)

Result

Deliverables:

All plastic parts and control panels for the Kyber Crystal Container
Precision machined 1mm POM-C (700+ parts per container)
Control panels with Aurebesh text and aluminum buttons
Production delivered on time (2 months)
Large format vacuum tabledesigned and manufactured (internal tool, reusable)

Impact:

Contribution to aworldwide collector's item(Death Star Central Tourbillon)
Production within a tight deadline with a particularly difficult material to machine
Technical innovation: development of specific tooling (vacuum table) to meet the need
Parts integrated into a case sold with an internationally prestigious collector's watch

This project demonstrates: