Custom Modular Metal Stage Platforms for The Nutcracker

Construction and metal fabrication are not always limited to residential or commercial projects. Some work requires a different mindset — one that combines engineering precision, safety, mobility, and artistic intent. This project is a perfect example.

For a major touring ballet production of The Nutcracker, we fabricated two custom modular metal stage platforms. On stage, these structures form Mother Ginger’s skirt — a large rolling scenic element that is pushed onto the stage during the performance and becomes an active part of the choreography.

This was not a decorative prop, but a fully functional, load-bearing stage construction designed for constant touring across the United States.

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Project Requirements

From the outset, the project came with strict technical and operational requirements.

Safety First

The structure operates directly on stage, in close proximity to dancers, including children. This required:

• Smooth, rounded edges with no sharp corners

• High structural rigidity with zero flex or wobble

• Stable behavior during movement and positioning

Any compromise in safety was unacceptable.

Daily Assembly and Disassembly

The production tours continuously, with performances in different cities almost every day. The platforms needed to be:

• Fully modular and demountable

• Capable of being assembled and disassembled daily

• Resistant to wear, deformation, and loss of geometry over time

Precision had to be maintained after dozens of assembly cycles.

Mobility on Stage

Mother Ginger’s skirt is rolled onto the stage during the performance, which required:

• Balanced weight distribution

• Smooth rolling under load

• Reliable stability once positioned

At the same time, the structure had to remain visually light and unobtrusive under stage lighting.

Accurate Curved Geometry

The skirt’s circular shape is a key visual element of the character. Even small deviations in radius or symmetry would be immediately noticeable by the audience.

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Design and Engineering

Before fabrication began, the focus was on understanding how the structure would be used on stage — not just its dimensions.

Engineering considerations included:

• Load calculations and safety margins

• Center of gravity and dynamic forces

• Modular connections and alignment

• Transport and storage constraints

Special attention was given to the curved steel elements, which define the silhouette of Mother Ginger’s skirt and required precise bending and consistent geometry across all sections.

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Fabrication Process

The platforms were fabricated using steel profiles, selected to provide high rigidity while keeping the overall weight manageable.

The fabrication process included:

• Precision cutting of all steel components

• Custom bending of curved frame elements

• Professional welding with full penetration

• Grinding and smoothing of all welds and edges

• Continuous geometry checks during assembly

Each platform was built as a modular system, allowing:

• Fast and repeatable assembly

• Easy replacement of individual components

• Safe and efficient transportation

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Mobility and Stage Operation

The completed structures were installed on heavy-duty casters designed for:

• High static and dynamic loads

• Frequent rolling during performances

• Stage-safe operation without damaging flooring

The caster configuration ensures that the platform:

• Moves smoothly and predictably

• Remains stable once positioned

• Can be safely handled by stage crew

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Touring and Transport Preparation

Because this is a touring production, transport durability was a critical part of the project.

The finished platforms were:

• Carefully packaged

• Protected with stretch wrap

• Prepared for repeated loading, unloading, and long-distance travel

These structures are not static installations — they are working theatrical tools designed for real-world touring conditions.

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Why This Project Is Special

Projects like this demonstrate how metal fabrication and construction skills can be applied beyond traditional building environments and into the world of performing arts.

Being involved in a production seen by audiences across the country is both a technical challenge and a professional privilege. It is especially rewarding to know that dancers and stage crews rely on a structure built with precision, responsibility, and craftsmanship.

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Project Summary

• ✔ Two modular metal stage platforms

• ✔ Designed as Mother Ginger’s skirt for The Nutcracker

• ✔ Fully demountable and touring-ready

• ✔ Engineered for safety, mobility, and durability

• ✔ Fabricated in Los Angeles

If you need a custom metal structure, a non-standard frame, a stage platform, or a project that requires engineering-level thinking rather than off-the-shelf solutions, we are always open to challenging and unique work.

Contact us to discuss your project and develop a technically sound solution.