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The Origins of the Air Blade

The Air Blade is a color guard spinning prop uniquely designed for school districts and independent groups with strict zero-tolerance policies that only allow “non-weapon” props. Made from virtually indestructible ABS plastic and reinforced with sonic-welded interior seams, the Air Blade combines strength and durability with a modern, arch-like shape that adds versatility to any performance. This design allows performers to seamlessly transition between classic rifle spins, turns, waves, and even experimental choreography.

collage of photos of the air blade in pop culture including glee and the lady gaga halftime show

Since its debut in 2008, Band Shoppe’s exclusive Air Blade Spinning Prop has become a staple in marching band and winter guard shows and even appeared on TV, including Glee (Season 4, Episode 2 “Britney 2.0”) and Lady Gaga’s Super Bowl LI Halftime Show. But have you ever wondered about the story behind the Air Blade?

Understanding the Design of the Air Blade

In the early 2000s, the rise of zero-tolerance policies made it increasingly challenging for scholastic groups to incorporate traditional color guard rifles and sabers into their performances. With limited alternatives available, many groups turned to homemade solutions crafted by creative band parents and volunteers. In May 2005, Band Shoppe’s product development team, led by Julie Mitchell and Jay Pearison, embarked on creating the first school-safe spinning prop to replace traditional color guard weapons. Known as the “Scimitar Design Project,” the initiative began with feedback from local instructors and a simple hand-drawn sketch, envisioning a dynamic prop that would meet both safety standards and performance needs.

The first drawings of the Air Blade.
Kenny Fisher marching as a drum major in Cynthiana, Indiana.

To bring the concept to life, the team sought a skilled craftsman to create a prototype. Woodworker and sculptor Kenny Fisher, whose designs and interpretations of the Lambing Chair are celebrated across North America, Western Europe, Australia, and New Zealand, was the ideal choice. Beyond his artistry, Kenny’s experience as a former drum major gave him a deep understanding of the mechanics and balance required to spin a prop in sync with a marching band, making him uniquely suited for the task.

Choosing the Right Materials  

Starting with that initial sketch, Kenny hand-carved the very first prototype from lightweight foam. However, the development team quickly discovered that the first design needed adjustments; the bar in the stock’s base interfered with handling, and the delicate blue foam proved unsuitable for rigorous testing. Undeterred, the team refined the design and began again with a more durable foam material. Over the next few months, Kenny crafted several new high-density foam prototypes, each bringing the prop closer to its final form. 

Under Jay and Julie’s guidance and with Kenny’s skilled craftsmanship, the team honed the design to achieve an ideal balance of strength, visual appeal, and functionality. During the process, 20 prototypes were meticulously crafted, tested, and refined before arriving at the final version. From there, Kenny then hand-carved the final design from the same laminated North American Poplar wood, the traditional material for color guard rifles. “It looks like a futuristic sword or even a Klingon weapon,” people commented. Simple, elegant, and innovative, the design was unlike anything the color guard world had seen before. 

And the laminated wood prototypes were very strong but there was just one MAJOR problem—they weighed over six pounds. 

prototypes of the Air Blade in pink and blue foam and wood prototypes
Initial prototypes of the Air Blade.

Back to the Drawing Board

To address the issue of weight, the team turned to mechanical engineers for guidance on innovative construction methods and alternatives to laminated poplar. The engineers recommended ABS plastic, known for being strong yet lightweight, to give the prop durability without adding extra weight. Using a technique inspired by manufacturing instrument cases, the team adopted a process called thermoforming. This involves molding polyurethane foam in a custom shape, using a combination of heat and pressure to form and set the material, creating a sturdy and balanced prop ideal for color guard routines. Plus, ABS eliminated the weight variances known to plague traditional wooden rifles. As an added bonus, ABS can still be spray painted using plastic-safe paints so instructors can change colors without adding weight or breaking the budget; one can easily paint up to 10 props.

The final missing piece: a technique called sonic welding. This method joins the ABS plastic parts seamlessly, fusing them without the need for adhesives. Sonic welding gives the Air Blade a strong, unified structure built to endure the high-impact demands of color guard routines.

No Turning Back

With this final breakthrough, the construction reached a professional-grade standard, achieving the ideal balance for smooth spins and precise handling. It was time to transition the “Scimitar Design Project” into production. To make this happen, Band Shoppe had to invest in digital 3D renderings with precise measurements to create a custom-tooled mold made specifically for this project. Recognizing the significance of the project, the team decided it was time to secure their investment, and, in the summer of 2007, Pearison Inc. filed a patent for the innovative new twirling prop design. 

The first 3D renderings of the Air Blade

But the work wasn’t complete yet, the new prop needed a name. After using the name “The Scimitar” throughout development, the team felt it didn’t quite capture the essence they wanted. They were looking for a name that suggested the agility of a saber without tying it to a specific type of sword—something that conveyed lightness and movement, inspired by the distinctive cutouts in the blade’s design. After brainstorming ideas on the whiteboard, the team landed on the name “Air Blade.”

Introducing the Air Blade

In the spring of 2008, after three years of dedicated work, Band Shoppe introduced the groundbreaking—and now patented—Air Blade to the public, transforming the way people viewed traditional spinning props like color guard rifles and sabers. 

Although some die-hard traditionalists were initially skeptical, the response was overwhelmingly positive. The Air Blade offered a practical alternative, enabling students to learn traditional weapons techniques preparing students for future opportunities in drum corps, coaching, or independent performances while still adhering to school policy guidelines. For instructors, the Air Blade unlocked new creative possibilities, allowing them to integrate fresh aesthetics into their shows to enhance themes and concepts with both functional and artistic versatility.

Jennifer Cortez, former Color Guard Instructor, wrote in her article “Embracing the Air Blade” for colorguardeducator.com[1]“If you have spent any time spinning the Air Blade, it is easy to notice it is comparable to a circle. Eliminate the need to define a front, back, top or bottom and the choreography opens up with infinite many ways to create routines that incorporate integrating the equipment with unique grips.” 

A New Era in Color Guard Performance

From concept to reality, the Air Blade’s journey demonstrates Band Shoppe’s commitment to innovation and its dedication to supporting the evolving needs of color guard teams. Born from a desire to provide a safe, versatile, and visually striking alternative to traditional weapons, the Air Blade has become a fixture in countless performances. Its unique construction—blending durability, lightweight design, and creative adaptability—has redefined what’s possible in color guard routines.

Since its debut, the Air Blade has empowered performers and instructors alike, offering students valuable training in weapons techniques without conflicting with school policies while opening new avenues for choreography and visual expression, allowing for dynamic routines that captivate audiences.

Now a staple on the field and in indoor performances, the Air Blade continues to inspire, standing as a testament to the power of creative problem-solving and the importance of adaptability in an ever-changing landscape. As marching arts programs evolve, the Air Blade remains ready to meet their needs, bringing both tradition and innovation into perfect harmony.


[1]  “Embracing the Air Blade”. colorguardeducator.com. Archived from the original on 02/22/2009.


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