{"id":9544,"date":"2026-11-02T09:40:17","date_gmt":"2026-11-02T14:40:17","guid":{"rendered":"https:\/\/smartpress.com\/blog\/?p=9544"},"modified":"2026-11-03T17:31:19","modified_gmt":"2026-11-03T22:31:19","slug":"print-production-goes-airborne-at-red-bull-flugtag","status":"publish","type":"post","link":"https:\/\/smartpress.com\/blog\/features\/print-production-goes-airborne-at-red-bull-flugtag","title":{"rendered":"Print Production Goes Airborne at Red Bull Flugtag"},"content":{"rendered":"<!--the_content--><!--block-empty--> <div class=\"row center-xs\"> <div class=\"col-xs-12 col-sm-11 col-md-8\"> <div class=\"row center-xs\"> <div class=\"col-xs-12 col-sm-10 col-md-8\"> <p>Print production isn&#8217;t always about what comes off the press. Sometimes, it takes a giant paper airplane, a little problem-solving and a whole lot of creativity to show what print can do. And our print got wiiings!<\/p> <p>&nbsp;<\/p> <p>For Red Bull Flugtag 2026, Smartpress and our parent company, <a href=\"https:\/\/thebernardgroup.com\/\" target=\"_blank\" rel=\"noopener\">The Bernard Group (TBG)<\/a>, teamed up to bring The Paper Airplane to life. With branded printed graphics, sustainable material choices and in-house design and fabrication, we put our capabilities to the test. Did it fly? Keep reading to find out\u2026<\/p> <p>&nbsp;<\/p> <p><a href=\"https:\/\/smartpress.com\/shop\/all\">Explore Smartpress\u2019 print products<\/a>.<\/p> <p>&nbsp;<\/p> <p>&nbsp;<\/p> <h2>Key Takeaways<\/h2> <ul> <li><a href=\"#designing-print-that-pushes-boundaries\">Smartpress and TBG combined their design, engineering and print production expertise to bring The Paper Airplane to life<\/a>.<\/li> <li><a href=\"#custom-printing-takes-flight\">Vibrant CMYK-inspired graphics and large-scale printing helped turn the giant paper airplane into a showstopper<\/a>.<\/li> <li><a href=\"#built-with-sustainability-in-mind\">The plane\u2019s Reboard construction showcased the potential of sustainable, paper-based materials<\/a> in ambitious structural projects.<\/li> <\/ul> <\/div> <\/div> <\/div> <\/div><!--block-empty--> <!--graybar--><div class=\"ltGrayBkgd-md\"><\/div><!--\/graybar--> <!--block--><div class=\"row center-xs\"><div class=\"col-xs-12 col-sm-8\"><div class=\"row\"><div class=\"col-xs-12\">\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<\/div><\/div><\/div><\/div><!--\/block--> <div class=\"row center-xs\"> <div class=\"col-xs-12 col-sm-11 col-md-8\"> <div class=\"row center-xs\"> <div class=\"col-xs-12 col-sm-10 col-md-8\"> <p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone\" src=\"https:\/\/blogprodproxy.wpengine.com\/wp-content\/uploads\/2026\/10\/2026-11-04-BLOG-1.jpg\" alt=\"The Smartpress flying machine jumping off the Red Bull Flugtag platform.\"   \/><\/p> <p>&nbsp;<\/p> <h2>What is Red Bull Flugtag?<\/h2> <p>Red Bull Flugtag is a unique flying competition where creativity, engineering and a willingness to take a leap &#8211; literally &#8211; come together. Teams design and build human-powered flying machines, then launch them off a nearly 30-foot flight deck into the water below. The goal? Fly as far as possible (or nosedive spectacularly).<\/p> <p>&nbsp;<\/p> <p>Since its debut in 1992, Flugtag has become a global event celebrating inventiveness, flight and a healthy dose of showmanship. For the 2026 Minneapolis event, our very own Full Bleed Flyers brought their oversized creation to the challenge: The Paper Airplane.<\/p> <p>&nbsp;<\/p> <p>&nbsp;<\/p> <p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone\" src=\"https:\/\/blogprodproxy.wpengine.com\/wp-content\/uploads\/2026\/10\/2026-11-04-BLOG-2.jpg\" alt=\"Smartpress' Red Bull Flugtag team wearing CMKY jumpsuits next to their airplane.\"   \/><\/p> <p>&nbsp;<\/p> <h2>Meet the Team<\/h2> <p>The Full Bleed Flyers set out to put Smartpress and TBG\u2019s design, engineering and print production capabilities to the test while giving a childhood classic a seriously ambitious makeover. The team included:<\/p> <ul> <li>Structural Designer Gabi Meissner<\/li> <li>Equipment Maintenance Mechanic Kyle Peabody (our fearless pilot)<\/li> <li>Fixture Development Manager Megan Renner<\/li> <li>Product Development Manager Jordan Valley<\/li> <li>Product Developer Tom Wasiljew<\/li> <\/ul> <p>As a 100% employee-owned company, we\u2019re no strangers to thinking big and taking ownership of ambitious ideas. And this project was no exception:<\/p> <p>&nbsp;<\/p> <p>\u201cWe wanted to create a craft that incorporates the materials we work with day to day, as well as showcase the creativity and capabilities TBG has to offer,\u201d said Valley.<\/p> <p>&nbsp;<\/p> <p>And as Meissner put it, the project was also a chance to prove what happens when a team is willing to take on something completely new: \u201cOf course none of us has ever built a plane before, but I think it shows we aren\u2019t going to back down from a challenge.\u201d<\/p> <p>&nbsp;<\/p> <p>From concept to construction, The Paper Airplane was a chance to push beyond the usual and show what happens when employee-owned ingenuity takes flight.<\/p> <p>&nbsp;<\/p> <p><a href=\"https:\/\/smartpress.com\/blog\/features\/esop-the-benefits-of-printing-with-an-employee-owned-company\">See what it means to be employee-owned<\/a>.<\/p> <p>&nbsp;<\/p> <p>&nbsp;<\/p> <p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone\" src=\"https:\/\/blogprodproxy.wpengine.com\/wp-content\/uploads\/2026\/10\/2026-11-04-BLOG-3.jpg\" alt=\"Smartpress' Red Bull Flugtag airplane printed in CMYK colors on display.\"   \/><\/p> <p>&nbsp;<\/p> <h3>The Paper Airplane at a Glance<\/h3> <div class=\"sp-table-wrap\"> <div class=\"sp-table\" role=\"table\"> <div class=\"sp-table__head\" role=\"row\"> <div class=\"sp-table__cell sp-table__cell--first\" style=\"text-align:center\" role=\"columnheader\">Wingspan<\/div> <div class=\"sp-table__cell\" style=\"text-align:center\" role=\"columnheader\">Length<\/div> <div class=\"sp-table__cell\" style=\"text-align:center\" role=\"columnheader\">Weight<\/div> <\/div> <div class=\"sp-table__row\" role=\"row\"> <div class=\"sp-table__cell sp-table__cell--first\" style=\"text-align:center;font-family:'DINProLight',sans-serif;letter-spacing:normal\" role=\"cell\"><span class=\"sp-table__label\" aria-hidden=\"true\">Wingspan<\/span>20 ft.<\/div> <div class=\"sp-table__cell\" style=\"text-align:center\" role=\"cell\"><span class=\"sp-table__label\" aria-hidden=\"true\">Length<\/span>12 ft.<\/div> <div class=\"sp-table__cell\" style=\"text-align:center\" role=\"cell\"><span class=\"sp-table__label\" aria-hidden=\"true\">Weight<\/span>100 lbs<\/div> <\/div> <\/div> <\/div> <div role=\"cell\"><\/div> <p>&nbsp;<\/p> <h2 id=\"designing-print-that-pushes-boundaries\">Designing Print that Pushes Boundaries<\/h2> <p>The concept was simple: Take the humble paper airplane and make it full bleed.* The execution? A little more complicated. How do you use humble paper products to create a human-powered aircraft that stands up to the structural demands of a 20-foot wingspan and a 12-foot-long body?<\/p> <p>&nbsp;<\/p> <p>That\u2019s where TBG\u2019s in-house display and fixture design expertise came in. The team used 3D modeling, structural design and prototyping to work through the details, testing and refining the design along the way.<\/p> <p>&nbsp;<\/p> <p>\u201cMany people think printing is flat, but at TBG we take flat things and make them dimensional. A giant paper plane seemed like the best way to display our capabilities to the world,\u201d said Peabody.<\/p> <p>&nbsp;<\/p> <p>The body was built entirely from Reboard, with Samba fabric covering the wings. This meant it was strong but super lightweight and recyclable, too (more on that later): \u201cA good amount of prototyping was involved to get the design right so the plane would be structurally sound and not break apart mid-air,\u201d said Wasiljew.<\/p> <p>&nbsp;<\/p> <p>This <a href=\"https:\/\/smartpress.com\/blog\/features\/5-ways-large-format-printing-can-transform-your-business\">large format printing<\/a> project called for the same attention to detail we bring to everyday creative print projects &#8211; just on a considerably bigger canvas.<\/p> <p>&nbsp;<\/p> <p>*In the print world, <a href=\"https:\/\/smartpress.com\/support\/printing-basics\/bleed-borders\">full bleed<\/a> means the printed content goes all the way to the edge of the page.<\/p> <p>&nbsp;<\/p> <p>&nbsp;<\/p> <p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone\" src=\"https:\/\/blogprodproxy.wpengine.com\/wp-content\/uploads\/2026\/10\/2026-11-04-BLOG-4.jpg\" alt=\"A man sitting in front of two computer monitors showing an airplane design mockup.\"   \/><\/p> <p>&nbsp;<\/p> <h2 id=\"custom-printing-takes-flight\">Custom Printing Takes Flight<\/h2> <p>If the plane was going to look like a giant paper airplane, it should look like it came straight off the press, too. The artwork took its cues from the print production process:<\/p> <p>&nbsp;<\/p> <p>\u201cThe concept revolved around the printing process and <a href=\"https:\/\/smartpress.com\/support\/color-ink\/color-space\">CMYK<\/a>,\u201d said 3D Design Coordinator Roscoe McLaughlin. \u201cSpecifically bringing in printing motifs like the color halftone, registration marks and color bars into the final graphics.\u201d<\/p> <p>&nbsp;<\/p> <p>The artwork was scaled up and adapted across the plane\u2019s unusual dimensions and surfaces, with vibrant colors and dripping paint effects giving the impression that The Paper Airplane had just rolled off the press. The result was a project that put Smartpress\u2019 capabilities to work in a decidedly unconventional way.<\/p> <p>&nbsp;<\/p> <p>And it wasn\u2019t just about making the graphics big. The artwork had to work across different materials and surfaces, too: \u201cSomething that really wowed me was how saturated and vibrant the print came out, especially on the cloth-wrapped wings,\u201d said McLaughlin.<\/p> <p>&nbsp;<\/p> <p>It\u2019s a great example of what happens when creative print projects get a little room to breathe &#8211; and in this case, fly (hopefully).<\/p> <p>&nbsp;<\/p> <p>&nbsp;<\/p> <p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone\" src=\"https:\/\/blogprodproxy.wpengine.com\/wp-content\/uploads\/2026\/10\/2026-11-04-BLOG-5.jpg\" alt=\"Smartpress employees using screwdrivers on their Red Bull Flugtag airplane.\"   \/><\/p> <p>&nbsp;<\/p> <h2 id=\"built-with-sustainability-in-mind\">Built with Sustainability in Mind<\/h2> <p>Making a giant paper airplane fly is one thing. Trying to make it as sustainable as possible is another. From the start, the team knew the materials would have to do more than look good &#8211; they had to hold up to the demands of a human-powered aircraft.<\/p> <p>&nbsp;<\/p> <p>\u201cWe knew we wanted to use sustainable materials that were going to be light and durable enough to take flight,\u201d said Valley.<\/p> <p>&nbsp;<\/p> <p>And that\u2019s what they did: The plane\u2019s body was built almost entirely from Reboard, a paper-based material that made up about 95% of the aircraft. Samba fabric covered the wings, giving the team a lightweight surface for the printed graphics while keeping the overall design practical for flight.<\/p> <p>&nbsp;<\/p> <p>Flugtag also gave the team a chance to use sustainable print materials in a pretty unconventional way. Rather than treating sustainability as an afterthought, it was part of the design conversation from the beginning.<\/p> <p>&nbsp;<\/p> <p>\u201cIt&#8217;s made almost entirely of paper-based and sustainable materials,\u201d said Valley, \u201cshowing the strength of paper!\u201d<\/p> <p>&nbsp;<\/p> <p>It\u2019s a fitting example of how TBG and Smartpress approach projects: Find the right materials for the job, explore what those materials can do and see how far a little creativity can go.<\/p> <p>&nbsp;<\/p> <p><a href=\"https:\/\/smartpress.com\/pages\/social-responsibility\">Sustainability is in everything we do &#8211; see how<\/a>.<br \/> <\/div> <\/div> <\/div> <\/div> <!--block--><div class=\"row center-xs\"><div class=\"col-xs-12 col-sm-8\"><div class=\"row\"><div class=\"col-xs-12\">\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<\/div><\/div><\/div><\/div><!--\/block--> <div class=\"row center-xs\"> <div class=\"col-xs-12 col-sm-11 col-md-10\"> <div class=\"row center-xs\"> <div class=\"col-xs-12 col-sm-10 col-md-8\"> <iframe style=\"width: 100%; aspect-ratio: 16\/9; height: auto; border: 0;\" title=\"YouTube video player\" src=\"https:\/\/www.youtube.com\/embed\/qXlpvbtjRWk?si=4QQm0N9v64rrj0d9\" allowfullscreen=\"allowfullscreen\"><\/iframe><br \/> <\/div> <\/div> <\/div> <\/div> <!--block--><div class=\"row center-xs\"><div class=\"col-xs-12 col-sm-8\"><div class=\"row\"><div class=\"col-xs-12\">\n<p>&nbsp;<\/p>\n<\/div><\/div><\/div><\/div><!--\/block--> <div class=\"row center-xs\"> <div class=\"col-xs-12 col-sm-11 col-md-8\"> <div class=\"row center-xs\"> <div class=\"col-xs-12 col-sm-10 col-md-8\"> <h2>So&#8230; Did it Fly?<\/h2> <p>After all the print production, prototyping, problem-solving and building, it was finally time to find out whether The Paper Airplane could actually do what it was designed to do.<\/p> <p>&nbsp;<\/p> <p>The short answer? It flew. The slightly longer answer? Not for very long. Let\u2019s just say all the Red Bull we drank didn\u2019t exactly give us wings.<\/p> <p>&nbsp;<\/p> <p>But the flight itself was only one part of the experience. Weeks of designing, building, custom printing and preparing for the big day brought people from across TBG and Smartpress together in ways that speak to our employee-owned values.<\/p> <p>&nbsp;<\/p> <p>\u201cYou expect the time on the flight deck to be wild, but the unexpected part was all the fun behind the scenes with all the building and preparation we did,\u201d said Renner.<\/p> <p>&nbsp;<\/p> <p>&nbsp;<\/p> <h2>Pushing the Limits of Print Production<\/h2> <p>From a simple paper airplane concept to a 20-foot flying machine, The Paper Airplane brought together TBG\u2019s design, engineering and development expertise with Smartpress\u2019 print production capabilities to turn an ambitious idea into something people could see, touch and watch take flight (however briefly).<\/p> <p>&nbsp;<\/p> <p>\u201cThis entire project was a true testament to TBG&#8217;s core values and capabilities,\u201d said Wasiljew. \u201cIt showed that when we come together, we truly can achieve amazing feats.\u201d<\/p> <p>&nbsp;<\/p> <p>And speaking of feats, Valley would like to see the team take to the skies once more: \u201cI\u2019m hoping to assemble the Full Bleed Flyers again for future events and see what other limits we can push as a team!\u201d<\/p> <p>&nbsp;<\/p> <p>The best parts of participating in Red Bull Flugtag?<\/p> <ul> <li>Meissner: \u201cThe Flugtag project says a lot about how we work at TBG. This project took a great deal of creativity, design and engineering to achieve our awesome finished product.\u201d<\/li> <li>Peabody: \u201cIt was the best team building exercise I have ever been a part of. We each used our expertise in different ways, but there was collaboration every step of the way!\u201d<\/li> <li>Renner: \u201cBetween the meetings, building, skit practice and costume making, it was a blast and it was so much fun to SHIP IT off the flight deck together!\u201d<\/li> <li>Valley: \u201cThe hype around the company was so awesome to see. People from all over TBG and Smartpress were legitimately excited for this event!\u201d<\/li> <li>Wasiljew: \u201cTeam members throughout the company seemed to really enjoy watching the plane&#8217;s samples being built, seeing the test flight of the first plane&#8217;s proto and watching us practice our performance outside in the grass.\u201d<\/li> <\/ul> <p>Whether it\u2019s our own print projects or our clients\u2019, wowing people is what Smartpress and TBG are all about.<\/p> <\/div> <\/div> <\/div> <\/div><!--block-empty--><!--\/the_content-->","protected":false},"excerpt":{"rendered":"Print production isn&#8217;t always about what comes off the press. Sometimes, it takes a giant paper airplane, a little problem-solving and a whole lot of creativity to show what print can do. And our print got wiiings! For Red Bull Flugtag 2026, Smartpress and our parent company, The Bernard Group (TBG), teamed up to bring The Paper Airplane to life. With branded printed graphics, sustainable material choices and in-house design and fabrication, we put our capabilities to the test. Did it fly? Keep reading to find out\u2026","protected":false},"author":8,"featured_media":9599,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"sfsi_plus_gutenberg_text_before_share":"","sfsi_plus_gutenberg_show_text_before_share":"","sfsi_plus_gutenberg_icon_type":"","sfsi_plus_gutenberg_icon_alignemt":"","sfsi_plus_gutenburg_max_per_row":"","footnotes":""},"categories":[8],"tags":[],"class_list":["post-9544","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-features"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.8 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Print Production Goes Airborne at Red Bull Flugtag - Smartpress Blog<\/title>\n<meta name=\"description\" content=\"Print production isn&#039;t always about what comes off the press. 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