This project was developed in response to a common challenge on film sets: repositioning extremely large, high-output light sources safely, accurately, and without costly downtime.

Modern film productions often use 24kW HMI fixturesmounted high on cranes or large rigs. While these lights provide enormous output, adjusting their position traditionally requires lowering the entire fixture, making changes, and then raising it again — a time-consuming and disruptive process, particularly on complex rigs with multiple units.

At the time, there were very limited motion solutions available on the market capable of handling fixtures of this size and power. Working closely with one of our clients, we set out to design a remote motion head that would allow these existing lamps to remain rigged in place while being repositioned and focused remotely.

Project Requirements

The key requirements were clear:

• Support an existing 24kW HMI fixture

• Provide remote pan (X), tilt (Y), and focus control

• Operate reliably while mounted high on cranes and rigs

• Withstand heat, mass, and environmental exposure

• Be cost-effective enough for real-world production use

This was not just an electronics project — it required a deep integration of mechanical, mechatronic, and motion-control engineering.

Prototyping and Mechanical Design

Development began with rapid proof-of-concept prototyping, using constructional aluminium to explore structural layouts, load handling, and centre-of-gravity behaviour. With fixtures of this size, understanding how the lamp behaves around different pivot points was critical to ensuring safe, smooth motion.

Heat management was another major challenge. High-power HMI lamps generate significant heat, and any electronics placed within the heat path risk failure. From the outset, the mechanical layout had to physically separate sensitive electronics from high-temperature zones.

Motion System Development

The motion system was designed around performance, safety, and cost constraints. EMP has experience across a wide range of motion technologies — from small stepper or DC motors to industrial servo systems — and this project required careful selection of motors, gearboxes, and actuators that could handle the load without pushing the unit beyond a viable price point.

Final Mechanical Architecture

The final design features:

• A structurally robust frame designed to support the full mass of the fixture

• Integrated cavities to house motors, gearboxes, and control electronics

• A large motor-driven slew ring to safely manage rotation

• Electronics housed in a side arm, away from the primary heat source

• Sealed design considerations for outdoor use and reduced ingress risk

Unlike some competing designs that place electronics above the lamp, this layout significantly improves thermal reliability by moving control systems away from rising heat.

Engineering, Analysis, and Manufacture

Once the overall form was finalised, the project moved into detailed engineering:

• Full mechanical drawings

• Structural and stress analysis

• Electronics and motion control design

• Custom PCB and software development

Due to the physical scale of the components, structural fabrication was carried out by a trusted manufacturing partner. All parts were then returned to EMP for full in-house assembly, integration, and testing, ensuring the final product met our performance and quality standards before release.

Skills and Expertise

This project brought together multiple disciplines:

• Mechanical and mechatronic engineering

• Motion control and robotics integration

• Electronic hardware and PCB design

• Embedded software development

• Partner-managed heavy fabrication

All system integration, electronics, and final validation were completed in-house.

Timeline and Outcome

Despite the complexity, the project had a very short turnaround. From initial concept to a fully working unit ready for production use took under three months. Rapid prototyping, in-house expertise, and strong manufacturing partnerships made this possible.

The result is a high-power remote motion head capable of safely and precisely controlling 24kW HMI fixtures, dramatically reducing rigging downtime and giving lighting designers and DOPs far greater creative control on set.