Theatre proscenium modules — repeatable joints for touring

Scenography panels requiring repeatable alignment across load-in cycles, with a premium painted finish readable under stage lighting.

Scenography
Multi-part assembly
Finishing

Modules

Largest single face

1.6 × 0.9 m

Primary process

FDM + paint + crating

Problem

The scenic designer needed large readable relief at a controlled budget, but the set had to survive repeated assembly without edge chipping or joint creep.

Constraints

Tight truck pack, only two technicians on site, and a matte finish that could not hotspot under LEDs.

Solution

We produced interlocking modules with metal-reinforced corners, printed alignment bushings, and a paint system staged for fast touch-up on tour.

Production process

CAD alignment fixtures → print batches optimized for color consistency → dry-fit in studio → edge sealing → hardshell travel frames → load-in checklist.

Final result

Twenty-six modules shipped with zero rework on first load-in. Joint lines remained within spec after six cycles.