Podcast Summary: But Why – How Big Is a Macy’s Parade Balloon?

Podcast: But Why: A Podcast for Curious Kids
Episode Date: November 14, 2025
Host: Jane Lindholm (with co-hosts, child questioners, and special guests)
Featured Guest: Will Koss, Executive Producer of the Macy’s Thanksgiving Day Parade

Episode Overview

This episode goes behind the scenes at the Macy’s Parade Studio in Munaki, New Jersey, answering kid-submitted questions about the famous giant balloons of the Macy’s Thanksgiving Day Parade. Host Jane Lindholm and her team tour the studio, speak with parade artists and engineers, and dive deep into what it takes to design, build, and fly the beloved parade balloons and floats.

Key Discussion Points & Insights

1. The Enormity of Parade Preparation

• Timeline: Preparing for the parade takes almost two years, involving artists, sculptors, carpenters, and designers.
• Studio Size: The Macy’s Studio is 80,000 square feet – roomy enough to fit a house 50 times over.
  • Quote: “We work together as a community to execute one of the largest and most fantastic parades in America.” – Will Koss (04:13)

2. Parade Floats: Construction, Transportation, and Magic

• Float Design: Floats are constructed to appear as if they’re 'floating' down the street. They often reach 30 feet tall and have skirts to cover the wheels, enhancing the illusion (09:45).
• Logistics: Each float folds down to about the size of a school bus (9x12 ft) to fit through tunnels and streets. Cranes in NYC reassemble them on-site the day before the parade (10:32).
  • Quote: “We take all of our floats from New Jersey, through the Lincoln Tunnel… and that’s where we reassemble everything. Sort of like a LEGO puzzle right on the streets the day before parade.” – Will Koss (10:32)

3. Creation Process: Materials, Sculpting, and Painting

• Sculpting Magic: Giant characters start as blocks of styrofoam, shaped with kitchen knives, hot wires, and then “candy coated” to protect against the weather (13:13).
  • Quote: “We call it a candy coating, sort of like an M&M on the soft shell. And it gets painted all pretty.” – Cameron Carnevale, Lead Sculptor (13:29)
• Paint: Over 2,000 gallons of paint are used, with custom mixes for unique shades (12:01).

4. Balloon Studio: How the Giants Are Made

• Unique Material: Macy’s balloons use a proprietary fabric, thicker than a tarp but designed specifically for strength and flexibility (19:21).
  • Quote (in fun, secretive tone): “It’s magic material for the Macy’s Thanksgiving Day Parade balloons.” – Will Koss (19:34)
• Size: Balloons reach up to 70 feet long (Spider-Man) or over 60 feet tall (Minnie Mouse).
• Assembly: Some require over 200 pieces, fused by heat sealers guided by coded patterns and miniature 3D models (21:00).
  • Quote: “We use a series of letters and numbers as codes to go ahead and build… and we also have really fun little miniature models of the balloons that also help us put the pieces together.” – Jen, Balloon Fabricator (22:45)
• Painting: Balloons start white and are painted by hand to bring them to life (23:28).

5. Character Selection and Parade Surprises

• Parade organizers choose a mix of beloved and new characters each year. Recent additions highlighted: Mariette, Shrek (returning), Pac-Man (his first year), and Buzz Lightyear (24:34).

6. Storage and Maintenance of Balloons

• After the parade, balloons are carefully deflated, rolled, and stored in massive hampers for future use (25:19).
• Each balloon is treated like part of the parade “family.”

7. The Science: Why Do Balloons Float?

• Principle: Balloons rise because they are filled with helium, a gas lighter than air (27:53).
• Physics: Despite being hundreds of pounds, the volume of helium in a 70-ft balloon allows it to float.
  • Quote: “Our Macy’s parade balloons float because we put something called helium inside of the balloon. It’s a gas that’s lighter than air… We just do them in a giant form. So there’s a lot of helium, a lot of gas that goes into the balloon, which allows it to float up in the air.” – Will Koss (27:53)

8. How Do They Stay Tethered? Balloon Handling & Safety

• Tiny Strings, Big Team: Each balloon has up to 90 handling lines, each held by a person, all connected securely with reinforced fabric patches (29:38).
• Safety: Additional carts and “vehicle patches” anchor balloons for extra security in case of wind or if handlers let go (30:54).
• Selection: Handlers must meet certain physical standards; all are Macy’s employees or friends/family (33:47).

9. Parade Day Operations: Communication & Weather

• Roles: Each balloon has pilots and flight managers to monitor wind and direct lowering/raising as needed (31:46).
• Communication: Loud voices, hand signals, and whistle signals are used during the parade.
  • Quote: “We’ve tried headsets. We’ve tried a variety of communication devices. Just projecting and raising your voice seems to be the most effective way to get the communication across.” – Will Koss (32:31)
  • Whistle Codes: One or two chirps raise/lower balloons, three chirps mean stop (32:51).

10. The Human Effort: Numbers & Traditions

• Over 5,000 people are involved in the parade, from performers to technical staff (33:47).
• The episode closes with a discussion of traditions and how the parade connects people during the holidays.
  • Quote on favorite parade moment: “My favorite part of the parade has to be what we call step off, which is the moment we say, three, two, one, confetti blows. And it’s the official start to the parade.” – Will Koss (35:09)

Notable Quotes & Memorable Moments

• “That’s intentional. Yes… we’re headed out to our 80,000 square foot studio where all of our balloons, our floats, and all of the other theatrical elements are designed and made.” – Will Koss (05:01)
• On foam sculpting: “We use a bunch of things, from kitchen knives to sort of a hot wire that will cut through the foam.” – Cameron Carnevale (13:15)
• “Each balloon starts out white and then gets painted by hand. After it’s all put together, the paint really brings the balloons to life...” – Jane Lindholm (23:28)
• “We have over 90 tiny strings on any one giant balloon… and each one of those strings gets held by a person which walks the balloon down the parade route.” – Will Koss (29:38)

Timestamps of Important Segments

• [02:10] Parade overview, preparation details
• [04:00] Introduction to Will Koss and his role
• [05:01] Macy’s studio walkthrough: departments and workspace
• [09:45] What is a parade float? How do they transport them?
• [12:01] The paint studio and amounts used
• [13:29] Foam sculpting techniques and “candy coating”
• [16:37] Entering the balloon studio
• [19:21] The special material for parade balloons
• [21:00] Construction, heat sealing, coded assembly
• [24:34] New and returning parade characters
• [25:19] Storage and “parade family” treatment
• [27:53] Science: Why balloons float (helium explanation)
• [29:38] Handling lines, number of handlers, safety
• [31:46] Weather, pilots, and communication during the parade
• [32:51] Whistle and hand signal system explained
• [33:47] Costume room, participant requirements
• [35:09] Will Koss’s favorite parade moment (“step off”)

Final Thoughts

The episode captures the awe-inspiring scale and teamwork behind one of America’s greatest parades, satisfying kid curiosity with clear, friendly, and sometimes playful answers. The discussion gracefully blends engineering, artistry, and tradition—celebrating the wonder that Macy’s Thanksgiving Day Parade brings to people of all ages.

For a visual rundown, check out video highlights on the But Why Kids YouTube channel. And remember, stay curious!