Aero Motion Australia designs and produces custom rigging systems for aerial performance across stage, theatre, circus, and screen. With deep roots in aviation and an unrelenting pursuit of visual wonder and technical mastery, the company continues to redefine what’s possible in the air—creating elegant, mechanical solutions for complex motion.

For the theatrical performance, Puppet Master - Into Thin Air, Aero Motion developed a uniquely manual rigging system design capable of supporting dynamic, three-dimensional flight on multiple planes of axis, without relying on motors or automation. The system combined an overhead catenary or dual running slacklines, diversion pulleys and compound rigging pulleys with 4:1 advantage that assisted with the lifting of the aerial artist, and bungies to create an expressive movement language suited to the show’s surreal themes.

At the core of the design was an overhead catenary dual rope running span line system or slackline engineered with mechanical advantage—a rope-and-pulley method that amplifies the operator’s lifting force, allowing the artist to be flown by hand. The performer was suspended from a rolling point mounted mid-span, enabling single-plane, multi-axis flight. This setup produced a pendulum-style motion across the stage, with the performer rising from an offset floor position interacting with a ground based artist and ‘floating’ through space.

To push beyond a linear flight path, a secondary tangential rigging system was introduced. This added an orbital layer of motion by tethering to the rolling point, allowing the performer to traverse complex arcs. Coordinating both systems demanded not just technical precision but also a skilled human counterweight operator—something Aero Motion believes can be trained within circus and stunt rigging disciplines.

To assist with vertical movement along the Z-axis, custom-built bungy cords connected a corset-style harness to a circular spreader bar, providing elastic lift and responsive recoil that enhanced the rigging’s mechanical rhythm. These bungy cords are hand-crafted using raw materials similar to those found in AJ Hackett-style systems, tailored specifically for aerial performance applications.

The construction method is intricate, carefully calibrated to achieve the desired elasticity, rebound characteristics, and overall dynamic response required for the choreography. While highly effective in delivering a fluid and energetic performance, the bungy rubber is inherently prone to wear. As the cords stretch and recoil, the energy exerted under tension generates internal heat, which gradually degrades the rubber from the inside out. Because of this, each bungy rope has a limited operational lifespan and must be closely inspected and monitored for signs of fatigue or damage before every use.

Swivels enabled the spreader bar to spin freely. As the performer’s rotational speed increased, the system exhibited a striking physical effect—gyroscopic precession. This phenomenon is the change in orientation of the rotational axis of a spinning object when an external force is applied. Rather than moving in the direction of the force, the spinning object responds 90° later in the direction of its rotation, introducing new rigging geometry and layout design challenges. Aero Motion addressed this by offsetting the rig’s secondary tangential rigging system geometry to allign this to contain the full X-Y-Z motion envelope within a 15-meter (50-foot) high studio space.

With the full spectrum of the rigging universe engaged, Puppet Master - Into Thin Air became a rare example of immersive, live performance engineering, where rigging, choreography, and physics converged.

Technical Details for Engineers & Riggers:

• Primary System: Overhead running span line or slackline span, with 2:1 to 4:1 mechanical advantage pulley system, no automation, operated manually. Rolling point is a dual pulley on both overhead running catenary lines that rolls along the span, Kernmantle static rope 11mm diameter is used throughout the system 

• Flight Domain: Single-plane pendulum flight with a radial rigging system manipulating the main system.

• Secondary System: Tangential tether to rolling point enables X-Y movement in arc, requires human counterweight operation for control.

• Vertical Control: Custom elastic bungies in parallel, fitted to a bespoke circular spreader. Rotation produces gyroscopic precession.

• Considerations: Operator training essential. Flight path management requires anchor point offsetting and clear stage-to-roof clearance of ~15m. No load cell integration. Relies on operator feel and controlled descent/lift.

For more information:

Aero Motion Australia

Watch Puppet Master - Into Thin Air

Author Bio: Gavin “Wild” Smith is the founder of Aero Motion Australia, a specialist in custom aerial rigging for circus, stunt, theatre and aviation environments. With a background in both engineering and mechanical systems as well as creative performance, his work bridges the gap between engineering precision and artistic expression. Gavin’s rigging designs have featured in live events, feature films, and high-risk helicopter operations around the world.