Define the animatronic’s purpose, size, range of motion, and performance requirements
Design the character, internal structure, and movement sequence
Create detailed sketches, CAD models, and mechanical layouts
Select materials for the frame, skin, joints, and outer finish
Build the internal support frame and mounting points
Install motors, servos, pneumatics, or hydraulics as needed
Add gears, linkages, cables, and bearings for motion transfer
Integrate sensors, controllers, power supply, and wiring
Program movement timing, synchronization, and control logic
Fabricate the exterior shell, face, limbs, and coverings
Assemble all mechanical and electronic components
Test each movement individually and adjust alignment
Calibrate speed, range, force, and motion limits
Add safety features, emergency stop controls, and protective covers
Paint, texture, and finish the exterior
Perform full-system testing and refine performance
Maintain, inspect, and repair components regularly