Tears, Tools & Tiny Towns: What We’ve Been Up To at Castle & Cubby

REVAMPING THE WORKSHOP

Three and a half years ago, we made a big move. From our original 300m² workshop into a space five times the size. It was a huge leap for us.

We put a lot of thought into the layout, planning for the flow of work and for what we would need in the future. We honestly did our absolute best. But the truth is, we were learning as we went. We had never run a manufacturing business before. We were figuring out lean management principles, setting up our first inventory management system, and just trying to make it all work.

As it turns out, we got a few things wrong.

We ended up making it further to walk instead of closer. We carved up the space with too many walkways. Not everything had a proper home, which meant a lot of wandering around trying to find things. It all added up to a lot of double handling and wasted time.

We did look at bringing in Lean Consultants to help us rework things. They were great, and I am sure in much bigger businesses they would absolutely be worth the investment. But for us, being bootstrapped and trying to keep things lean, the costs were simply out of reach. Government grants that had previously helped small businesses with these types of improvements had also dried up.

So we looked inwards. We realised we already had the answers. We just needed the time and about $50K worth of reasons to finally do it ourselves.

This year, we made it our big goal to kick the year off right with a massive move of literally everything in the workshop.

And it was not just a tidy-up. We moved every single thing. Every shelf, every machine, every storage unit. We also finally introduced our barcode system to manage an inventory of more than 10,000 components.

What we thought would take a month ended up taking two and a half.

But it was completely worth it.

The workshop now runs better than ever. The workflow is smoother, the space is cleaner, the working areas are bigger, and the whole place just feels better to be in. The team is loving the new setup, and we are in a much stronger position now to tackle the exciting projects ahead.

A big reason for doing this overhaul now was to prepare for the arrival of two new machines coming in May:

• Automated Docking Machine: This will improve safety, precision, and speed when cutting timber, and help us reduce waste significantly.

• CNC Machine: This will allow us to produce even more components in-house, opening the door to greater innovation and flexibility.

We are incredibly grateful to our clients for their patience and understanding during this transition. Your support means the world to us, and we cannot wait to show you what comes next.

OUR LATEST PRODUCTS

Designing products that spark creativity and support learning is at the heart of what we do. We have been busy dreaming, building, and refining to bring some exciting new ideas to life. Here is a peek at what has just landed and what has had a fresh new upgrade:

Outdoor Classrooms
Built to make outdoor learning not just possible but powerful. These spaces are designed to inspire both educators and students, bringing the freedom of fresh air together with thoughtful, practical design.

Play-Based Learning Villages
Our ever-popular village setups have a new neighbour. The Sushi Shop has just moved in, joining favourites like the Hospital and Food Truck, and opening up even more playful possibilities for imaginative role-play.

The Modern Cubby House
A beautiful blend of simplicity and style. This new design features sleek perspex sliding windows and bi-fold windows, creating a modern, airy space for children to play, imagine, and unwind.

We fall head over heels for every new creation we bring to life. But nothing beats seeing them settle into their new homes. Each one is a reflection of our passion for creating playful, purposeful spaces where children can learn, grow, and connect with the world around them.

learning through collaboration

Some of the most rewarding parts of what we do come from the conversations we have with the real experts. The ones living and breathing education and play every single day.

We are constantly inspired by the educators, school leaders, and passionate advocates who put play right at the centre of kids’ learning, exactly where it should be.

Over the past few months, we have been lucky enough to connect with some incredible voices in this space. From early childhood specialists to principals leading real change in their communities, these conversations have been nothing short of inspiring. They shape everything we do. How we design, how we build, and how we make sure what we create is not just beautiful to look at, but meaningful and practical in real-world learning environments.

One chat that really stuck with us was with the principal at Gilgai Plains Primary School. Their whole community has been transformed through our play-based installations. Think Food Truck, Hospital, Sushi Shop! Their story is one we cannot wait to share with you in an upcoming video. It is heartfelt, powerful, and a real reminder of why we do what we do.

We have also been diving deep into the world of outdoor classrooms, speaking with educators about the benefits of teaching out in the open air. The insights have been brilliant, and we are excited to share more soon. It is a story worth telling, and one we hope will inspire even more schools to embrace learning outside the four walls.

BEING REMINDED OF Why WE DO WHAT WE DO

Some moments remind us exactly why we pour our hearts into Castle & Cubby. Attending the opening of a bespoke play space at Keysborough Gardens Primary School earlier this year was one of those unforgettable moments.

We were invited to their grand opening, and it genuinely moved us. Being welcomed into our clients’ stories like this is, quite honestly, the best part of what we do. I found myself capturing videos and photos of the kids playing, laughing, and throwing themselves fully into the space. More than once, I had to wipe away a few tears. It was one of those full-circle moments.

After years of hard work, taking risks, and building something we deeply believe in, not just for ourselves but for our team and for the children we design for, seeing it all come to life was something else. Happy staff, delighted customers, and kids radiating pure joy. It pulled on every heartstring.

This was not just any play area. It was thoughtfully designed to be inclusive, welcoming children of all abilities, including those with disabilities and sensory sensitivities. Watching them explore so freely, with confidence and wonder, was incredibly moving.

Projects like this are why we do what we do. They make every long night, every hard decision, and every leap of faith worth it. Knowing we have helped create a space where children can feel safe, inspired, and truly happy is the real reward.

We cannot wait to share more of this story with you.

welcoming new faces

With all the exciting growth happening at Castle & Cubby, expanding our team has been just as important as expanding our product range. We are thrilled to welcome three new faces who are already making their mark.

Pip joined us just over three months ago in our Sales and Customer Service team, and she has hit the ground running. From day one, she has wowed customers with her product knowledge, thoughtful communication, and incredible eye for detail. She has also brought a quiet, and quirky can-do attitude that adds a total vibe to the office. We feel so lucky to have her onboard.

Jacob, our new Customer Success Manager, brings an infectious energy and a genuine passion for creating outstanding customer experiences. He has slotted right in, building strong relationships with our clients and helping to lift the whole customer journey to a new level. He is already adding huge value, and we are so glad he is part of the crew.

And last but absolutely not least, Breely. She has come on board to join me in Marketing and is already proving to be my go-to, get-it-done, creative right-hand gal. From the moment she stepped in, she has brought fresh ideas, amazing energy, and a real knack for turning plans into action. I cannot wait to see where we take things together.

On another exciting note, we have been brewing up something special — Welcome Packs.

It is an idea I have had percolating for a while, and it is finally coming to life. Each pack will include our care guides, a treat for the kids, and a few lovely perks from like-minded eco-conscious partners like Tint Paint, Little Potion Co., and Tara’s Treasures. It is our way of saying thank you, and adding a little extra joy to your Castle & Cubby experience.

looking ahead

The road ahead is shaping up to be just as exciting as it is full. With new team members settling in, our upgraded workshop coming to life, and fresh machines about to come online, we are gearing up for the next big chapter with focus and momentum.

At the heart of it all is our mission. To create meaningful, sustainable products that bring people together and spark imagination. We do not always get it perfect on the first go, but we are here for the long game. We are learning, evolving, and showing up every day with a commitment to doing things better.

Thank you for being part of this incredible journey with us. We are so grateful to have you along for the ride.

With love,
Kel x