• Manufacturing Speed: The standard production lead time for a ball of this immense size and complexity is 8-10 weeks.
• Logistical Complexity: A piece of this size and weight requires specialized crating and ocean freight, which typically takes 4-6 weeks alone.
• Uncompromising Quality: Despite the time pressure, the centerpiece had to be absolutely flawless. As the most visible element in the club, any imperfection would be unacceptable.

We immediately cleared a primary production line in our custom fabrication workshop. The project was assigned a dedicated team of our top three master craftsmen, who worked in extended shifts to build the reinforced fiberglass core and meticulously hand-apply over 25,000 individual A-grade mirror tiles. We implemented a 24-hour curing cycle using infrared lamps to accelerate the adhesive bonding process without compromising strength.

Simultaneously, our logistics team determined that ocean freight was not an option. They immediately began sourcing options for chartered air freight, a complex undertaking for an item of this size and weight. They designed a custom, flight-safe, shock-absorbent crate and handled all the complex customs pre-clearance documentation while the ball was still being built.

Despite the rush, our quality control process was enhanced. The finished ball underwent a 48-hour continuous rotation and balance test with its paired 500kg motor to ensure perfect equilibrium and flawless performance. The piece was signed off by our Head of Engineering personally.

The crated mirror ball was transported to the airport and loaded onto its chartered cargo flight. Our team provided the client with real-time tracking from our factory door to the Berlin airport. The piece arrived in Berlin at the beginning of week 6, a full 72 hours ahead of the client's final installation deadline.