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NDE Clarke Pitchline supports major theatrical production

The challenge

A high-profile, immersive theatrical production in London required advanced mechanical systems to power dynamic stage elements, including rotating platforms, the central performance stage and automated scenery transitions. These features were essential to deliver a strong visual spectacle and maximise audience engagement during multiple weekly performances.

The production engineering team encountered several key technical requirements:

• High reliability demands: Equipment needed to withstand frequent operational cycles with minimal risk of failure to avoid disruptions to the performance.
• Space constraints: Compact solutions were essential due to limited space backstage and within central stage housings
• Smooth and quiet operation: Components had to function with low noise and vibration to avoid any impact on audience experience
• Custom solution: Off-the-shelf parts and assemblies were inadequate - fully bespoke designs were required for the limited operating window

The solution

NDE was selected as the engineering partner for its specialism in mechanical power transmission solutions, where the company boasts more than five decades of experience.

The NDE team’s expertise in custom driveline components for demanding applications across various industries positioned them perfectly for this entertainment sector project.

NDE Clarke Pitchline’s engineering team worked in close collaboration with the production's engineering team and a third-party project management team to manufacture, supply and install specialised driveline equipment:

• Universal driveshafts: Custom-engineered units designed to transmit torque across misaligned axes, enabling smooth rotation of key stage platforms. These featured high torque capacity and built-in vibration damping in shafts to manage dynamic loads from movement and the central stage
• Gear couplings: Flexible, misalignment-tolerant couplings which connected motors to drive systems for scenery automation, providing a high-torque coupling solution in a small operating window.

• Gearboxes: Compact bespoke high-ratio gearboxes, optimised for precise speed control, high torque and repeatability of positioning
• Machined line shafts & open gearing: NDE’s in-house machining capability meant machined parts such as gears and splined line-shafts could be machined to meet strict deadlines

The installation included on-site assembly, alignment, and comprehensive testing both at NDE’s facility prior to delivery and on-site. NDE's engineers ensured full compatibility with the existing electrical and control infrastructure, while all components met relevant safety and performance standards, including features for reduced operational noise.

The result

The supplied driveline equipment delivered reliable, trouble-free performance across hundreds of performances, with no major mechanical issues reported. This dependability allowed the production team to focus on creative delivery and audience experience. The client praised the components' robustness, ease of maintenance, and overall contribution to operational uptime.

This project highlighted the NDE team’s ability to meet customer demands and requirements through their mechanical power transmission expertise.