Blending Art and Engineering for Las Vegas’ Grandest Stage

Michael Curry Design is a puppetry design and entertainment company — known for making large- and small-scale puppets for projects spanning from the original Lion King musical to attractions at Universal Studios. They joined forces with Loupe to produce a massive animatronic phoenix for Awakening — a groundbreaking show at Wynn Las Vegas. Featuring a 360-degree stage and some of the most sophisticated sets ever assembled, Awakening demanded nothing short of perfection.

THE NEED

The Mechanics of Magic

Michael Curry is no stranger to animatronics, and handles most of its needs inhouse. But with a 60-foot wingspan, logistic complexity, and no room for error, the phoenix pushed the boundaries of their inhouse capabilities. As the show’s grand finale, the animatronic bird needed to captivate audiences with its grace and scale, all while performing flawlessly night after night. We faced several unique hurdles:

• Size and Complexity: The sheer scale of the bird required a different level of control — bigger motors, faster motion, and interlocking systems for safety and reliability.
• Balancing Artistry and Engineering: Typically, industrial machines are built for function over form — but the bird’s expressions and range of motion needed to feel graceful and natural.
• Testing Constraints: Because this would be a one-off machine, there was no room for physical prototypes — and the bird had to work perfectly on its first live debut.
• Maintaining the Illusion: The phoenix appears to the audience seemingly out of nowhere — a dramatic entrance that added its own set of challenges and safety systems.

Compounding these challenges were pandemic-era supply chain delays that disrupted timelines. And with the show already announced and tickets already sold, stakes were high to hit our deadline.

THE SOLUTION

Control Systems for Seamless Performance

Collaborating closely with Michael Curry Design, Loupe approached the project with a blend of technical expertise and creative problem-solving. Since they already had a model of the bird in their animation software, the team was able to easily translate it into a program that integrated directly with the control system.

Mechanical components were meticulously designed to handle the phoenix’s immense weight and tension requirements. To orchestrate the bird’s intricate movements, we paired standard Loupe libraries with custom software. And by building a robust digital twin, we were able to make as much progress as possible digitally while waiting for parts during supply chain disruptions. This allowed the team to simulate and test the phoenix’s operations in real time, identifying potential issues and fine-tuning performance without relying on physical components.

This also enhanced operator training and safety: While operators could not directly see the machine, a thoughtfully designed web-based HMI offered intuitive controls and clear feedback. From the control booth, a Navigator system provided operators with real-time insights, ensuring flawless synchronization between the phoenix’s movements and the broader stage production.

THE RESULT

Awe-Inspiring Performance, Night After Night

Despite external delays, the phoenix soared into action right on schedule — embodying all the artistry and precision that Michael Curry Design envisioned. Awakening debuted as the largest theatrical production in Las Vegas in over 15 years, pushing the boundaries of live entertainment and setting a new standard for technology-driven theater.

“This was a singularly complex piece, so it wouldn’t have been surprising to require more troubleshooting. But it runs 10 times a week without issue.”

Shane Reetz
Automation Software Engineer, Loupe

The phoenix continues to perform with remarkable consistency, delivering shows night after night without downtime or malfunctions. Its operation is not only seamless but also easier for the team to manage than many of Michael Curry Design’s previous animatronics.

Loupe’s innovative approach ensured that even this ambitious creation remains reliable and user-friendly, blending the magic of storytelling with cutting-edge engineering.

Featured image provided by Wynn Las Vegas