Cast of Curiosities
I am in the process of launching a business that rents puppets for theatrical productions, helping theaters that may not have the time, budget, or resources to create them from scratch. By offering a diverse selection of high-quality puppets, I aim to make professional puppet integration more accessible for productions of all sizes. Additionally, the business will provide DIY kits complete with materials and an instructional video, designed specifically for youth productions. These kits will introduce kids to the fundamentals of kinetic sculptures and prop-making in a fun, approachable way, fostering creativity and hands-on learning.
The first puppets I am creating for rent will be for a production of James and the Giant Peach. Since scale is a key element in this show, the insect characters will be quite large, making them visually striking on stage. However, they will remain lightweight and simple to operate, ensuring that both adult and child actors can comfortably perform with them. My illustrations, included below, guide the design process to balance functionality with the whimsical, larger-than-life aesthetic needed for the production.
For the Ladybug puppet, I used an inflatable bladder to shape her body, keeping it lightweight while maintaining a full, rounded form. I created a pattern to house the ball bladder so that I can protect the bladder and sew attachments to the cover. Her head was crafted using two-part expanding foam, molded in a spherical concrete form for consistency. To ensure a seamless connection, I contoured the bottom of the head to fit the body using a serrated blade and carved out a cavity to house the eyes. To refine the mechanical details, I have been teaching myself 3D modeling programs like Fusion 360 and Meshmixer, which I used to render the claw sets, leg sets, antennas, and fangs. The antennas are printed in flexible TPU filament to prevent breakage if the head were ever dropped, while the other components are made from solid PLA for durability. Additionally, I designed a limited-motion joint for the elbows and knees to prevent hyperextension, ensuring smoother and more controlled movement.
For the Grasshopper puppet, I started by creating a 2D model to establish the correct scale. Using foam insulation sheets, I cut out the pattern pieces and shaped them with a rotary tool and rasp, hollowing them out to keep the puppet as lightweight as possible. To refine the form, I hand-sewed batting and fabric over the foam, softening the edges and giving it a more organic appearance. On select fabric pieces, I used my free-motion quilting foot on my sewing machine to add texture, mimicking the look of scales and an exoskeleton. The thigh pieces are attached with magnets, allowing for easy removal and transport. Meanwhile, the legs have been 3D modeled and printed, and they are now awaiting priming and paint to complete the final look.
For the Spider puppet, I used the same inflatable bladder and fabric cover technique as the Ladybug to keep it lightweight while maintaining its shape. The head was also molded using the same two-part expanding foam process as the Ladybug, ensuring consistency in durability and form. To create the legs, I modeled them in Fusion 360 and printed them on my 3D printer. Due to their large scale, I had to print them in segments and carefully glue the pieces together for a seamless structure. Instead of using the limited-motion joint I designed for other puppets, I opted for a flexible TPU filament to create a pin system. This allows the spider’s knees and ankles to bend while maintaining durability and flexibility, ensuring smooth, lifelike movement.
My most recent endeavor has been creating prototypes for K-12 friendly kits that introduce kids to the simplicity of kinetic sculpture. Through my work with children's theaters, I noticed a growing demand for chorus member props that are easy to make, require minimal involvement from theater staff, and help young performers learn the fundamentals of prop, mask, and puppet making. To address this need, I am developing a series of all-inclusive kits featuring several mask and puppet designs. Each kit will come with all necessary materials and an instructional video where I guide students through the creation process, sharing insights into prop-making techniques and the principles of kinetic sculpture.
