Creating kinetic metal sculptures that move reliably over time presents unique challenges for artists and engineers alike. One primary issue is material fatigue—constant motion stresses metal joints and hinges, leading to wear and potential failure. Environmental factors like temperature fluctuations cause metal expansion/contraction, altering carefully calibrated movements. Corrosion from moisture or pollutants degrades components, while dust accumulation interferes with smooth operation.

The engineering complexity grows when scaling up designs, as larger pieces require stronger (yet still precise) mechanisms. Finding the right balance between aesthetic vision and mechanical practicality often demands multiple iterations. Many artists struggle with maintaining consistent motion patterns as components wear down unevenly.

Power transmission poses another hurdle—whether using wind, motors, or human interaction, the energy source must deliver reliable force without compromising the sculpture's visual appeal. Proper weight distribution becomes critical to prevent excessive strain on certain parts while ensuring the entire piece moves as intended.

Regular maintenance requirements create additional challenges for permanent installations. Unlike static sculptures, kinetic works need periodic adjustments and part replacements, raising long-term cost and accessibility concerns. Despite these obstacles, successful kinetic metal sculptures achieve remarkable harmony between artistic expression and mechanical durability through innovative solutions.