Custom Animatronic Puppet
Date:
Type:
Sponsor:
September 2025 - Now
Senior Project
Dr. Brian Davis;
Cal Poly Mechanical Engineering Department and Cal Poly's ME Discretionary-Fund Allocation Committee (MEDAC)
This senior project focuses on the design and construction of a custom 18-degree-of-freedom audio-animatronic puppet capable of standing from a seated position. The system combines servo- and actuator-driven mechanisms for expressive facial and upper-body motion with pneumatic leg actuation to provide the force required for standing. Mechanical systems are designed in SolidWorks, character forms are digitally sculpted in ZBrush, and motion is programmed using Bottango. The animatronic integrates steel and 3D-printed components and is controlled via an Arduino-based system, emphasizing durability, expressiveness, and production-ready performance.
Special thanks to our mentors from:
Concept Art
Developed initial concept artwork to translate Dr. Brian Davis into an animatronic character in his chosen puppetry-inspired art style, establishing proportions, personality, and visual language.
Model Making
Created physical and digital models to study form, scale, and construction feasibility prior to full mechanical integration.
Drawing Package
This drawing package highlights technical drawings created in SolidWorks for a custom audio-animatronic system, focusing on mechanical integration, mounting features, and assembly. CAD modeling was completed in SolidWorks, while ZBrush was used for sculpting the character shells. Together, these tools supported the translation of expressive character design into precise, manufacturable components.
Mechanical CAD
Designed internal mechanical systems in SolidWorks, including actuation layouts, linkages, and structural components to support expressive motion.
Motion Programming
Programmed and tested character motion using Bottango, synchronizing mechanical movement with expressive performance and audio cues.
Artistic CAD
Sculpted the character’s exterior and facial features in ZBrush, refining surface detail, stylization, and alignment with the intended puppetry aesthetic.
Fabric and Clothing Design
Designed and fabricated custom fabric elements and clothing for the animatronic, balancing aesthetics, durability, and range of motion while ensuring compatibility with underlying mechanical systems.
Creating the Shells - CAD
Imported and refined shell geometry in SolidWorks, adding structural extrusions and mounting features for 1/4-20 bolts and M3 fasteners. Shells were segmented and cut to interface precisely with internal animatronic mechanisms, including custom designs for the eyes, legs, and arms.
Creating the Shells – 3D Printing & Finishing
Fabricated shell components using glass-fiber-reinforced nylon for strength and durability, then overlaid with fabric for a soft, character-appropriate finish. Foam was used to add volume and shape to the hair. Eyes were 3D printed in white ABS, smoothed using an acetone vapor chamber, and hand-painted to add expressive detail.
