Animatronics - Creature Creation

Creature Creation

Building the various components used in the animatronic device usually takes the longest time. There are four main categories into which the work splits, with development happening simultaneously across the categories. Although basically similar, the design and production processes for animatronics in cinema varies greatly from animation for theme parks and other permanent venues.

Mechanical

Engineers design and build the mechanical system, which includes everything from basic gears to sophisticated hydraulics.

Electronic

Another group develops the electronic control systems needed to operate the animatronic device. Typically starting from scratch and creating their own custom circuit boards, these engineers are essentially building giant remote-controlled toys. Almost all of the movement is manipulated by specialized remote-control systems known as telemetry devices.

Structural

All of the electronic and mechanical components need something to which to attach and control, and the skin must have a frame to maintain its shape. This is done by building a plastic and steel frame to increase the realism, and because it is the natural way to design it.

Surface

The "skin" is often made from foam rubber, which is a very light, spongy rubber made by mixing air with liquid latex rubber and then curing (hardening) it. While there are other compounds, such as silicone and urethane that are stronger and last longer, foam rubber is used because it is much easier to work with. The solution is poured into each mold and allowed to cure. As mentioned earlier, parts of the frame are embedded with the foam rubber at certain points. To further strengthen the skin, a piece of fabric is cut to size and embedded in the foam rubber after it is poured into the mold. Once cured, each piece of skin is pulled from its mold.