Life casting in animatronics
The unique techniques of natural casting have found favor in many other fields, such as tool prototyping, prosthetics, taxidermy, architectural restoration, and film and television special effects. The advanced technology used in animatronics also incorporates life launch techniques in the initial stages of character creation.
Animatronics refers to the manufacture and use of robotic devices to mimic a living being. Creatures can be humans, animals (like dinosaurs and sharks), plant life, or even mythical creatures. Animatronics bring real characteristics to inanimate objects so that they can walk, talk, and perform other activities naturally. The movements can be mechanized or controlled by computers.
Animatronics are used primarily in movies (20,000 Leagues Under the Sea, Jaws, ET, Jurassic Park, etc.), television, and advertising. This differs from computer animation in that the simulated creatures are physically present and moving in front of the camera. Characters from various amusement parks also surprise visitors with the help of animatronics.
Making the creatures
Animatronics use puppets, models, and other figures that are then animated to emulate realistic movements. The character first takes shape as a sketch on paper and scale models are created for approval.
Once approved, an internal support frame is carefully constructed using steel or even wood sometimes. Once the desired shape is achieved, the electronic and mechanical components are placed around the frame.
The figure is eventually covered with body shells that give it the shape and appearance of a real creature. The supple skin adheres to the outside of the figure completing the lifelike appearance.
The skin can be made of silicone, latex foam, or urethane. First a mold is made using alginate gold clay. The mold must be the exact size and shape of the animatronic figure. The molds can be made in parts to allow for greater ease of use.
The body cast is reinforced with plaster bandages to form a shell cast. Once cured, it is carefully removed from the mold and you will have captured the minute details that will be replicated in the leather mold. An alginate mold should be used quickly as it tends to shrink. The silicone or latex is poured into the mold and allowed to cure. Once fully cured, the thin-skinned cast can be easily removed from the mold as the alginate does not adhere to anything.
The cast will have a texture similar to real skin. It will also be flexible to allow for facial and body movements as needed. The stripped skin is cleaned and finished before being carefully attached to the figure.
The animatronic figure receives the final finishing touches in the form of eyes, teeth, hair, feathers and other such realistic features. The necessary color pigments can be added to the leather during the laundry itself. Otherwise, special silicone / latex paints are used to color the figure as needed.
The figure is ready and then animated as desired.