Building the FlySafe Belt: 12 Prototypes, One Mission — Keep You Safe

There’s something kind of magical (and mildly chaotic) about launching a brand-new product. It’s like juggling flaming knives on a unicycle — exhilarating, terrifying, and a little bit addictive. Especially when that product is something that literally has to save lives. The FlySafe Spotting Belt didn’t just pop into existence — it was forged in a swirling vortex of late-night design tweaks, foam scraps, Velcro tests, and a LOT of coffee.

I knew from day one that safety wasn’t negotiable. When you're flipping humans through the air, your gear can’t just look good — it has to hold up under pressure. Literally. So I dove in. I sketched. I stitched. I tested. I failed. I repeated. I made not one, not two — but over twelve different prototypes before even thinking of calling it done.

Every version taught me something new. One had too much bulk. Another had stitching that wasn’t strong enough. One early prototype actually exploded mid-pop (don’t worry, no acroyogis were harmed in the making of this belt). Each time, I refined the design — a little less fluff here, a little more reinforcement there. And slowly, something solid began to emerge.

Finding a manufacturer that understood what I was building? That was a journey all on its own. Most factories were used to gym belts or climbing harnesses — not this weird, hybrid, human-launching, contact-heavy niche thing we call Acroyoga. The first manufacturer couldn’t quite hit the stitching specs I needed for real safety. So I made a tough call… and switched.

That led to the next twist: turns out the stitching required for this belt needs a very specific, heavy-duty machine. You can’t just use any ol’ sewing machine when you’re designing gear that has to stop a flying human mid-air. So — plot twist — I bought the machine. Yep. That’s how committed I am to this.

I’ve been hand-testing materials, experimenting with thread types, adjusting panel cuts and closures, all to make this thing just right. And if I’ve learned anything from building The AcroBack, it’s this: products evolve. The best ones should. That’s why I’m launching FlySafe in small batches. I want to stay nimble, listen to your feedback, and constantly upgrade the quality, materials, and feel.

I’m not interested in just pumping out gear. I want to craft it. Like, nerd-out-on-the-details, triple-check-the-stitching, hand-test-the-load kind of crafting. There’s a huge difference between “that’ll do” and “this is it.” And for a belt that someone might rely on to catch them mid-air, we don’t do “that’ll do.”

And here’s the thing — I love this. I love inventing. I love designing. I love when an idea turns into a real thing I can hold, tweak, and test. And I especially love when that thing helps the Acroyoga community grow safely, confidently, and creatively. This belt is just the beginning.

Because oh yes… I’ve got ideas. Lots of them. New gear, tools, accessories — everything designed with the acroyogi in mind. If you’ve ever had a moment mid-jam and thought, “I wish someone made a thing for this…” well, I probably already have it in my sketchbook. And I can’t wait to bring it to life.

Thanks for being part of this journey. The FlySafe Belt is my love letter to our community’s trust, strength, and flight. So here's to flying high, falling safely, and always building better.