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Project Overview
Working closely with the teams that manage mechanical props and puppets for theatre, we are often engaged in updating the current designs and mechanisms. Thanks to our experienced team and the advancements in modern CNC machinery, we have been able to deliver custom engineered solutions for theatrical productions that allow for more dynamic movements and controls for performers.
Background Information:
Featuring one of our projects, we partnered with a renowned theatre known for its intricate use of mechanical props. Our work focused on enhancing and developing custom-engineered solutions to help them continue delivering magical experiences. This included wearable puppets and masks with dynamic movements controlled by performers through an electromechanical system. Our team designed and now manufactures this system, ensuring seamless integration of traditional puppetry with modern machinery. Additionally, we design, manufacture, and supply the carbon fibre hinges and mounts essential for translating linear movements into the desired expressive actions.
These components are examples of how specialised custom fabrication for theatre productions can enhance the narrative and visual impact of a performance.
Objectives:
Our goal for the project was to increase the reliability of the current electromechanical system by re-designing to iron out the known problems, using tighter tolerances now achievable with our state-of-the-art machines, and becoming the sole vendor for this specific equipment for all shows.
Key Capabilities:
At AEC, we specialise in creating designs achievable with modern CNC machinery. As expert engineers, we understand the capabilities of machining and fabrication, which helps us deliver cutting-edge solutions in theatrical mechanical design. Our capabilities extend to include elements of custom rigging systems, custom fabrication for theatre productions, and automated stage machinery.
Management and Execution
Role of AEC:
Our primary role was to bridge the gap between artistic vision and the technical engineering required to bring it to life. We dedicated the time necessary to gain a deep understanding of the specific movements and effects required for the performance that the system needed to achieve. This understanding ensured that our mechanical and electromechanical systems would perform reliably under the rigours of live theatre.
Project Management:
This extensive project encompasses initial designs, prototyping, and large-batch manufacturing. It is an ongoing effort, with continuous design modifications to meet evolving requirements and better align with the specific needs of individual shows.
Team Involvement:
The successful delivery of this project relied on the collaborative efforts of our diverse team, drawing on expertise from various parts of our business. Initially involving our sales team to align the project scope to the client’s needs. We then shifted focus to the design team, who consulted with machine operators to confirm machining capabilities. Once the design was finalised, our production team took the lead in manufacturing, followed by assembly and quality control, all handled in-house to ensure everything met our standards.