How to Build an Animatronic Head Part 1 - Creating the Mechanical Underskull

FOR YOUR WORKSTATION

Headform - if you do not have a headform of your character, you can buy a generic one to use for this lesson

MATERIALS

Fiberglass cloth 6oz Heavy (2)

20min Epoxy

Plaster Bandage (for creating mold)4”x15” (3)

Mold Release

HEAD CORE

Water-based Clay like EM210 or WED

Clay modeling tools to cut clay, can even be plastic knife or butter knife

Disposable brushes for brushing epoxy (size will vary depending on your project)

Stir sticks or something for mixing epoxy

Disposable cups (paper or plastic) for mixing epoxy

Small bucket or any container to hold water for dipping plaster bandage

Paper towels

Krylon Crystal Clear spray (optional)

Disposable gloves (optional)

TEETH

Acrylic Resin Teeth: size 24

Jet liquid monomer to make gums (Davis Dental)

Jet powder

Key-To-Alginate fast set for molding (Davis Dental)

CHARACTER EYES

Eyes can be made from anything except glass - they need to be able to be drilled, cut and altered

Sample Eyes that would work well

SERVOS

Jaw Servo (Hitec HS-645MG)

Eyes Horizontal Rotate (Hitec HS-53)

Eyes Vertical Rotate (Hitec HS-82MG)

Eyelids 2 needed (Hitec HS-82MG) (2)

Brows 2 needed (Hitec HS-82MG) (2)

Upper lips 2 needed (Hitec HS-82MG) (2)

Mouth corners 2 needed (Hitec HS-82MG) (2)

Lower Lips 2 needed (Hitec HS-82MG) (2)

SERVO TRAYS

Birch Plywood 3/16 x 6 x 12

Birch Plywood ¼ x 12 x 24

#5 wood screws

MISCELLANEOUS

Eyebrow Wire 3/32” x 4:40 thread (Du-bro 6pack)

Eyebrow pushrod housing (Du-bro)

Ball Link Sockets 2/56 (Great Planes) (2)

Insta Cure cyanoacrylate 2oz

Insta Cure accelerator 2oz

Rod End (clevis) 2 pack

Dual Servo Horn #3342(Du-Bro) 2 pack

Goldenrod #507 .032” multi-strand cable

Goldenrod #508 .056” multi-strand cable (2)

E/Z Connectors 12 pack

Eye Lid Brass Strip .032” x ¼”

Eye Mech Brass Strip .064 x 1/4 brass strip (2)

Brass Strip .064 x 1/4 brass strip x 12”

Sand Paper 120 grit and 400 grit

Threaded Rod 2/56” x 12”

Threaded Rod 4.40 x 12”

Brass Rod 1/8” x 12”

TOOLS

BITS & INDEXES

2/56 Tap and handle (8. in image)

Drill bits (you will only need some of the smaller ones) (9.)

CLAMPING, CRIMPING & GRIPPING TOOLS

Needle nose Vise Grips (11.)

Needle Nose Pliers (12.)

Pliers (13.)

Tweezers (19.)

Vise (6.)

CUTTING TOOLS

Automatic Center Punch (you can use a nail instead) (18.)

Coping Saw (10.)

Cable Cutter (14.)

Flat Cutters (optional) (23.)

Hack Saw (16.)

Side Cutters (alternate for Tin Snips) (22.)

Tin Snips (21.)

Wire Cutter (15.)

Xacto Knife (20.)

ELECTRONIC TOOLS

Servo Tester with Battery pack (super useful) (5.)

MEASURING TOOLS

Ruler (1.)

Digital Veneer Calipers (Your most used tool!) (2.)

Adjustable Protractor (3.)

POWER TOOLS

Dremel Tool with Sanding Drum, Circular Blade, and grinders (24.)

Drill Motor (25.)

SCREWDRIVERS

Screw Drivers Flat and Phillips (17.)

WRENCHES

Allen Wrench Set (Inch and Metric) (4.)

NOTE:

Craig will also be using a Table Top Drill Press, a One Inch Belt Sander, and a Scroll Saw. However, these can be substituted with an electric hand drill(or Dremel Tool), sand paper, and a coping saw, respectively

 

HEALTH/SAFETY PRECAUTIONS

When working with toxic and/or dangerous materials or tools:

ALWAYS read labels for appropriate use guidelines

ALWAYS wear a high-grade respirator

ALWAYS work in a well-ventilated area

ALWAYS protect your skin

ALWAYS wear eye protection