Custom Furniture Fabrication Legoland Resorts
Custom Furniture Fabrication Legoland Resorts
The Legoland Hotels in Florida and California embody the imaginative and playful world of LEGO — designed to immerse families in a creative, story-driven environment. The challenge was to fabricate custom, themed furniture that not only captured the spirit of the brand but also met stringent hospitality standards for safety, durability, and usability.
To address this challenge, the PK SPACES team implemented a strategic Value Engineering (VE) process aimed at optimizing cost efficiencies without compromising the project’s aesthetic integrity or operational durability.
Partnering with the Merlin Entertainments team, PK SPACES led the custom fabrication of a wide range of bespoke, theme-driven furniture pieces, engineered to meet both the creative intent and the operational demands of high-traffic hospitality spaces.
Key Objectives
Develop and fabricate brand-aligned, themed furniture that adhered to Legoland’s creative vision and Merlin’s quality standards.
Ensure structural integrity and safety compliance, especially for interactive and kid-centric pieces.
Develop and fabricate brand-aligned, themed furniture that adhered to
Legoland’s creative vision and Merlin’s quality standards.
Maintain quality while responding to urgent logistics challenges tied to installation deadlines.
Our Approach
1. Collaborative Design Development
Working closely with the Merlin design and project teams, PK SPACES provided shop drawings, prototypes, and finish samples for approval. Each piece—ranging from themed bunk beds to play tables and Media units—was custom-engineered for durability and child safety, using commercial-grade joinery, rounded edges, and compliant coatings.
2. Material Engineering & Prototyping
To align with Legoland’s bright, playful aesthetic:
Solid MDF and hardwood frames were used for strength and precision shaping.
High-performance laminates and non-toxic paints were applied to achieve the brand’s vibrant color palette.
Embedded LEGO motif details and custom CNC patterns were incorporated for immersive storytelling.
3. Multi-Site Logistics Coordination
As Legoland Hotels in Florida and California were running on overlapping timelines, PK SPACES implemented a phased production and shipping schedule, aligning fabrication and installation sequences to the client’s master construction plan.
4. Crisis Response: Air Freight Execution
Due to compressed delivery timelines driven by client installation dates and opening deadlines, PK SPACES had to air freight complete furniture sets to site. This extraordinary measure ensured on-time delivery, but incurred an additional logistics cost exceeding $200,000 USD, underscoring the team’s commitment to client satisfaction and deadline integrity.
Key Success Factors & Results
- Compressed lead times threatened project delivery. Solution: Air freighted all furniture components internationally to meet fixed opening schedules.
- Maintaining structural integrity in highly customized designs. Solution: Reinforced joinery, CNC precision routing, and internal steel supports for durability.
- Balancing cost with brand accuracy. Solution: Material engineering using cost-effective substrates while achieving premium visual finishes
Metric | Goal | Outcome |
Design Alignment | Match Legoland’s brand aesthetic | Achieved through custom color, form, and detailing |
Safety & Durability | Hospitality-grade compliance | Exceeded ASTM standards |
Delivery Deadline | Pre-opening installation | Met, despite shipping constraints |
Air Freight Cost | N/A | $200,000+ incurred to meet deadlines |
Client Satisfaction | On-time, on-brand execution | Achieved 100% installation acceptance |
Outcome
Despite unprecedented logistical pressures, PK SPACES successfully delivered fully themed, custom-engineered furniture for three Legoland Hotels across the U.S., aligning with Merlin Entertainments’ creative vision and maintaining uncompromised quality.
The project demonstrated the company’s ability to merge creativity, precision engineering, and production agility, delivering on-brand results under complex global timelines.
