Balloon Master

In college, I majored in theater design and technology. Building sets gave me a lot of experience with carpentry. After I moved to New York, I applied to a job posting for a carpenter at the Studio and was hired. For two months leading up to that year’s parade, I built floats. I must have done a good job because they asked me to continue working for them.

Later, the head of the Studio looked at my theater-set design portfolio—a collection of materials that showcase a person’s past work. He then asked me to draft plans for the floats. After a few years, he asked me if I wanted to work on the balloons. Of course I did! When he retired, he handed the reins of the Studio to me.

We start by sketching the design of a balloon on paper. The drawing is then turned into a 3-D computer illustration. Based on the drawing, we build a small, physical model by creating an armature and sculpting clay around the outside of this metal skeleton. Or we use a 3-D printer, which builds up layers of a material, such as plastic, to make a solid object.

Next, we make two molds of the model. We paint one to look like the finished balloon and write technical information on the other. They’re the blueprint to create the fabric pattern that will become the balloon. These fabric pieces get sewn together and decorated with paint that has elasticity. When the balloon is inflated, the fabric will stretch. The paint needs to stretch with it.

We calculate the total weight of the fabric and paint needed to create the balloon. Then we determine the balloon’s volume. That lets us know how much helium we’ll need to fill it. If a balloon can’t hold enough helium to lift its weight, then we have to adjust the design to either reduce the weight or add more volume.

A lot of our balloons, like Snoopy and Olaf from the movie Frozen, are in a horizontal pose. This shape makes the balloons more aerodynamic. It allows air to flow smoothly around the balloon, rather than pushing against it, creating drag. This slowing force would make the balloon harder to pull along the parade route.

The horizontal pose also generates lift, or upward force. Some of our balloons are more vertical, such as SpongeBob SquarePants. But they still lean forward slightly to allow for airflow that helps create lift.

I love the moment when the parade begins and all the spectators start cheering. There’s nothing so exhilarating as hearing millions of people appreciating your work.