College - Author 1
College of Engineering
Department - Author 1
Mechanical Engineering Department
Degree Name - Author 1
BS in Mechanical Engineering
College - Author 2
College of Engineering
Department - Author 2
Mechanical Engineering Department
Degree - Author 2
BS in Mechanical Engineering
College - Author 3
College of Engineering
Department - Author 3
Mechanical Engineering Department
Degree - Author 3
BS in Mechanical Engineering
College - Author 4
College of Engineering
Department - Author 4
Mechanical Engineering Department
Degree - Author 4
BS in Mechanical Engineering
Date
6-2026
Primary Advisor
Rick Lasko, College of Engineering, Mechanical Engineering Department
Abstract/Summary
This project involved the design, fabrication, and implementation of a custom audio-animatronic puppet modeled after Dr. Brian Davis for the California Polytechnic State University Mechanical Engineering Department. The objective was to create an expressive, lifelike character capable of synchronized speech, head movement, arm gestures, and seated-to-standing motion while demonstrating the integration of mechanical design, controls, manufacturing, and artistic fabrication.
The final system consists of an 18-degree-of-freedom animatronic platform utilizing servo-driven facial and upper-body actuation combined with a pneumatic standing mechanism. A modular aluminum and 3D-printed structural framework was developed using SolidWorks and validated through engineering analysis. Character shells were digitally sculpted in Z-Brush and fabricated using glass-fiber reinforced nylon, then finished with fleece coverings and custom aesthetic features to achieve a stylized Muppet-like appearance. An Arduino-based control system, integrated with Bottango animation software, coordinated synchronized motion profiles and audio playback using over 20 minutes of recorded dialogue provided by the project sponsor.
The completed prototype successfully demonstrated synchronized speech, expressive motion, and reliable standing functionality during testing and public exhibition at the Cal Poly Senior Project Expo. The project met its primary objectives of creating a fully functional audio-animatronic character while providing a flexible and modular platform for future expansion. This work illustrates the successful integration of mechanical engineering principles, controls systems, additive manufacturing, and creative design in the development of an interactive entertainment system.
URL: https://digitalcommons.calpoly.edu/mesp/903
Project Video
Included in
Controls and Control Theory Commons, Electrical and Electronics Commons, Electro-Mechanical Systems Commons, Fiber, Textile, and Weaving Arts Commons