SUMMARY
Virtual production — the technique of filming actors in front of massive real-time LED displays rather than green screens — has become one of the most sought-after technologies in film and television. Popularized by productions like The Mandalorian, it requires enormous curved or flat LED walls that must be precisely positioned, reconfigured between shots, and moved through studio spaces without cranes or heavy equipment. In a feature for Linus Tech Tips, the team visited Pixomondo’s virtual production volume to explore how LED wall technology works — and Airfloat Air Skids played a starring role in how those massive panels actually move.
Watch This Project on YouTube
Per LED wall panel section — moved by hand
Multi-ton wall sections repositioned by 2–3 people
No overhead lifting equipment required on set
THE PROBLEM
- Large LED wall panels and structural frames are extremely heavy and awkward to maneuver in tight studio spaces
- Virtual production volumes require precise positioning of LED sections — off by an inch and the geometry doesn’t work
- Cranes and forklifts are impractical inside a finished production studio environment
- Traditional casters and skates risk damaging polished studio floors and can’t be steered with enough precision
- Frequent reconfiguration between shoots demands a fast, repeatable movement solution
THE SOLUTION
- Airfloat Air Skids placed under the structural base of each LED wall section
- Units float on a thin film of air and can be guided by hand to any position on the studio floor
- Full 360° omni-directional movement — panels can be rotated, slid, and nudged into precise alignment
- No floor damage; Air Skids distribute weight evenly and glide without marking the surface
- Small crew can reposition entire wall sections quickly between setups with no special equipment
Safety Improvements
Moving 2,000+ lb LED structures in a finished studio environment demands precise, safe handling at every step.
No crush hazard underfoot
Air Skids float at roughly the height of a steel-toe boot when pressurized — far safer than caster wheels, which can trap toes or fingers underneath during movement.
Locked down when off
When air supply is cut, skids settle directly onto the floor and the load is immobilized. No unintended drift or tip risk when the system is off — critical around expensive production equipment.
Dead-man pendant control
A quick-exhaust valve settles the load in about one second when released. Operators have immediate, reliable emergency stop capability at all times.
Precision without power
Because units float freely, even a small team can make fine position adjustments by hand — no powered equipment that could cause sudden, uncontrolled movement near fragile LED panels.
IMPLEMENTATION AND RESULTS
Featured in a viral Linus Tech Tips video. Airfloat technology is visible in action, reaching a massive global tech and production audience.
Large LED sections moved by a small crew, by hand. What would otherwise require crane rigging or heavy equipment was accomplished safely by 2–3 people with complete positional control.
No floor damage. The production studio floor was protected throughout setup and reconfiguration — no marks, gouges, or damage from casters under heavy loads.
Fast, repeatable repositioning. The team could reconfigure the LED volume layout quickly between shots, enabling a more flexible and productive production workflow.
Safe operation around expensive equipment. Air Skid movement is smooth, controllable, and stoppable in one second — critical when working around high-value LED panels and precision optics.
For more information about Airfloat Air Skid systems for entertainment and production environments, contact us today.
