Recent trends in animatronics along with superior CGI effects initiated a revolution in the film industry. Animatronics integrates various disciplines mechanical, robotics, anatomy and puppetry to boon lifelike characters.
Disney coined audio animatronics initially into public display in the early 1960s. Special effects, and 3D technology combined with animatronics characters formed mythical real-life characters. Animatronics have a wide scope in the entertainment and advertisement industry. Shortly, inanimate objects can be carried into realistic characters using advancements in animation cutting-edge technology. Electronic sensors, hydraulic levers, armature, electrical motor, pneumatics, and hydraulic motors are the general equipment used for the physique.
Some famous animatronic characters used in the film industry are Terminator in The Terminator: Judgement Day, Yoda in Star Wars: Revenge of the Sith, Na’vi in Avatar, tyrannosaurus in Jurassic Park Trex, E.T, King Kong, and Jaws.
Development stages of animatronics
Animatronics formation includes six development stages from the creation of a miniature model to the programming of the robot. Giant-sized animatronic is first demonstrated by a miniature model and then figured into full size with materialist covering.
Design and white paper are the initial and critical processes in the formation of model. The crew decides on the animatronics shape, design, features, quality of the movement and number of movement, how each movement will be exhibited. Detailed study of the model and characterisation analysis is the main factors to be decided before the formation of the sculpt. Budget, duration required and appearance of the animatronics, special effects required are decided from this white paper process.
Character shaping is the process where a miniature model is moulded to resemble the later full-sized animatronics. White paper drawing is converted into three-dimensional models with the same features and characters. This stage is required for alteration of character if required and for the redevelopment of the physique.
Moulding is the next development stage which decides the material used to build the robot. The skin material required and the inner parts are formed by steel or aluminium. Generally, skin material graphite fibre is covered with latex foam is used to cover the robot. It is decided on the factor considering single skin cover or multiple cover, hard or flexible, reusable or one use. This process is time-consuming since the robot must replicate the complicated real-life character.
Mechanisation is the next development stage to form movement and control in the giant model. Electrical motors, sensors, hydraulics, radio controllers, solenoids, levers, and rigs are used for the body, neck, and leg movement. Welding fabrication is done after deciding the mechanisation of the robot. Cold Weather and watery scenes are the real challenge to overcome. The sculpt might undergo an electric shock if not insulated appropriately.
Costuming is the design of the outfit showcase of the robot. Animation special effects are supported by designing the appropriate costume. The computer graphic interface makes ease of visualisation with accurate tailoring. Costuming is decided on the character’s features, shape and realism.
Programming and training of the robot is a tedious process. Input is given according to the movement required and parts to be moved in the screen. Best Programming interfaced with CGI penetrates the real visual character on the screen.
Illustration of Animatronics
Animatronics demonstrated by Stan Winston in Jurassic Park was well renowned and brilliant. Which set an example for future animatronic movies with the advancement of mechatronic systems and robotics. The crew built the miniature model of the tyrannosaurus to test its feasibility and later developed a full-sized lifelike character. Bob Gurr designed the giant-sized animatronic tyrannosaurus initially with mechanical motors. Since electric motors would not give the speed and stability required.
The crew opted for hydraulics to bring the lifelike characters. Created miniature design of tyrannosaurus robot. Mc Fadden system is used for flight simulation to control the movement of animatronics. The main factor to be considered is the weight of the animatronics and the material used. The system and the mechanic stage must be synchronized to ensure stability.
Aluminium or steel was the material choice to build the body of the Imagineering robot tyrannosaurus. Since Imagineer tyrannosaurus used the neck and leg mostly for the visual effect, spiral rings were used for the synchronized movement. The mechanism used in eye movement is radio-controlled. The skin was made of graphite fibre and covered by latex foam. For experiencing the realism of the character animatronics were used to exhibit breathing. Using lever push up and down under skin the demonstrated the breathing movement.
The whole-sized animatronic tyrannosaurus was 4 ft long, weighed 60 tons and could be raised to 24 ft in the air. Audio animatronics were the important support for the picture. The sound engineer gathered and used the live animal sound for the rumbling and movement of the dinosaur. Sound of waves, tiger, elephant trumpet and alligators were used. Apart from these, cold weather and snow were the main challenge for the crew
Advancement of animatronics is attainable through immersive video and CGI effects. The application of higher-end animatronics in the film industry would benefit higher growth in future.