Working as a staffer for Vulkon Conventions, Avilla was approached by Penny Juday in October 1995. She had seen his props on display at the show, and asked if he'd be interested in making light-up badges for another Paramount Pictures pilot project called The Osiris Chronicles, which he did. The pilot didn't sell, but was aired in 1998 as The Warlord: Battle for the Galaxy. Later on, Juday contacted Avilla to make some PADDs for Star Trek: First Contact. He eventually produced some 30 pieces for the movie, including a pair of dermal regenerators and several tricorders.