Abstract: A skin or skin system for a robot or robotics assembly is provided that includes one or more integral elastomeric links (or bars) (“IELs”) that are configured for receiving and connection with coupling elements or members (e.g., pivot pins) at the ends of mechanical links/bars. The IELs are also configured to act as a final link of a mechanical linkage made up of these mechanical links to provide a closed chain. For example, the body of each of the IELs, or a portion of the IEL body extending between connection points with the coupling elements of the links/bars of the mechanical linkage, provides a final link in a mechanical linkage forming a closed chain to allow it properly function.

Abstract: A skin or skin system for a robot or robotics assembly is provided that includes one or more integral elastomeric links (or bars) (“IELs”) that are configured for receiving and connection with coupling elements or members (e.g., pivot pins) at the ends of mechanical links/bars. The IELs are also configured to act as a final link of a mechanical linkage made up of these mechanical links to provide a closed chain. For example, the body of each of the IELs, or a portion of the IEL body extending between connection points with the coupling elements of the links/bars of the mechanical linkage, provides a final link in a mechanical linkage forming a closed chain to allow it properly function.

Abstract: A computer-implemented method is provided for physical face cloning to generate a synthetic skin. Rather than attempt to reproduce the mechanical properties of biological tissue, an output-oriented approach is utilized that models the synthetic skin as an elastic material with isotropic and homogeneous properties (e.g., silicone rubber). The method includes capturing a plurality of expressive poses from a human subject and generating a computational model based on one or more material parameters of a material. In one embodiment, the computational model is a compressible neo-Hookean material model configured to simulate deformation behavior of the synthetic skin. The method further includes optimizing a shape geometry of the synthetic skin based on the computational model and the captured expressive poses. An optimization process is provided that varies the thickness of the synthetic skin based on a minimization of an elastic energy with respect to rest state positions of the synthetic skin.

Abstract: A robot with an animated segment including a generally cylindrical structural frame. The frame includes a plurality of spaced apart plastic ribs that each have a curved or arcuate body that is arranged to be convex relative to a central axis of the structural frame. A first end of each rib is pivotally coupled with a lower ring, and a second end of each rib is pivotally coupled with an upper ring. A flexible outer covering is positioned over the structural frame and is attached to one or more of the ribs. This provides a robotic segment that is animated with an organic feel and natural movement by providing an actuator in the robot segment that is operated by a controller to move one or both of the rings such as linearly along a central axis of the structural frame (e.g., toward and away from the other ring).

Abstract: A method of fabricating a skin system or its elements using a laser cutter. The laser cutter is controlled to perform multiple passes to selectively cut away layers of material on a surface of a sheet of cellular foam materials. Each layer of material to be removed is defined by a cut or texture pattern. The laser cutter is operated to cut deeper with each layer of material removed by setting a different resolution for the laser cutter for each layer. For example, a laser cutter may be selectively controlled to operate within a resolution range, and each layer defined by the same or different cut pattern is cut using a different resolution. The method includes associating lower resolution settings for the first or outer layers to remove a first depth of material from the skin sheet's surface and associating higher and higher resolution settings for additional layers.

Abstract: A method for fabricating an artificial skin system such as skin for use with a robotics assembly. The method includes forming or accessing a digital three dimensional (3D) model of an object. The digital 3D model defines a topography of an exterior surface of the object. The method includes processing the 3D model to generate a 3D model of a core, including defining an exterior surface of the core with a topography that is an inverse copy of the topography of the exterior surface of the object. The method includes fabricating the core based on the core model, whereby the core has an exterior surface corresponding to the exterior surface of the core model. The core is used in dipping processes or injection molding processes to form a skin in which the exterior surface is formed of material that abutted the inverse topography of the exterior surface of the core.

Abstract: A method for fabricating an artificial skin system such as skin for use with a robotics assembly. The method includes forming or accessing a digital three dimensional (3D) model of an object. The digital 3D model defines a topography of an exterior surface of the object. The method includes processing the 3D model to generate a 3D model of a core, including defining an exterior surface of the core with a topography that is an inverse copy of the topography of the exterior surface of the object. The method includes fabricating the core based on the core model, whereby the core has an exterior surface corresponding to the exterior surface of the core model. The core is used in dipping processes or injection molding processes to form a skin in which the exterior surface is formed of material that abutted the inverse topography of the exterior surface of the core.

Abstract: A method for fabricating a product, such as an animatronic character, with artificial skin. The method includes providing data defining an exterior surface geometry of the product. A base geometry model of the product is generated based on the exterior surface geometry data, which in turn is used to fabricate a prototype of the product. Then, an exterior skin mold is formed using the product prototype mounted on an alignment block. The method includes fabricating an inner support structure based on the base geometry model having an exterior geometry smaller than the 3D base geometry model by the thickness of the exterior skin. The inner support structure is positioned within the mold with the inner support structure mounted upon the alignment block, which is received in the mold. The product is formed by pouring material for an exterior skin layer into the mold and over the inner support structure.

Abstract: A computer-implemented method is provided for physical face cloning to generate a synthetic skin. Rather than attempt to reproduce the mechanical properties of biological tissue, an output-oriented approach is utilized that models the synthetic skin as an elastic material with isotropic and homogeneous properties (e.g., silicone rubber). The method includes capturing a plurality of expressive poses from a human subject and generating a computational model based on one or more material parameters of a material. In one embodiment, the computational model is a compressible neo-Hookean material model configured to simulate deformation behavior of the synthetic skin. The method further includes optimizing a shape geometry of the synthetic skin based on the computational model and the captured expressive poses. An optimization process is provided that varies the thickness of the synthetic skin based on a minimization of an elastic energy with respect to rest state positions of the synthetic skin.

Abstract: A computer-implemented method is provided for physical face cloning to generate a synthetic skin. Rather than attempt to reproduce the mechanical properties of biological tissue, an output-oriented approach is utilized that models the synthetic skin as an elastic material with isotropic and homogeneous properties (e.g., silicone rubber). The method includes capturing a plurality of expressive poses from a human subject and generating a computational model based on one or more material parameters of a material. In one embodiment, the computational model is a compressible neo-Hookean material model configured to simulate deformation behavior of the synthetic skin. The method further includes optimizing a shape geometry of the synthetic skin based on the computational model and the captured expressive poses. An optimization process is provided that varies the thickness of the synthetic skin based on a minimization of an elastic energy with respect to rest state positions of the synthetic skin.

Abstract: An assembly adapted for visually disguising drive or support features of an amusement park ride or a display system using a drive to move a show element about a space. The assembly includes a platform and a drive mechanism for selectively moving a support member. The assembly also includes an object supported upon an end of the support member spaced apart from the drive mechanism, and the support member extends through a slot in the platform. The assembly also includes a canopy positioned between the supported object and a surface of the platform facing the supported object. The canopy blocks an observer from seeing the slot in the platform. The canopy includes a plurality of camouflaging elements positioned between the slot in the platform and the supported object, and the camouflaging elements are arranged in two or more layers.

Abstract: A method of fabricating a skin system or its elements using a laser cutter. The laser cutter is controlled to perform multiple passes to selectively cut away layers of material on a surface of a sheet of cellular foam materials. Each layer of material to be removed is defined by a cut or texture pattern. The laser cutter is operated to cut deeper with each layer of material removed by setting a different resolution for the laser cutter for each layer. For example, a laser cutter may be selectively controlled to operate within a resolution range, and each layer defined by the same or different cut pattern is cut using a different resolution. The method includes associating lower resolution settings for the first or outer layers to remove a first depth of material from the skin sheet's surface and associating higher and higher resolution settings for additional layers.

Abstract: An assembly adapted for visually disguising drive or support features of an amusement park ride or a display system using a drive to move a show element about a space. The assembly includes a platform and a drive mechanism for selectively moving a support member. The assembly also includes an object supported upon an end of the support member spaced apart from the drive mechanism, and the support member extends through a slot in the platform. The assembly also includes a canopy positioned between the supported object and a surface of the platform facing the supported object. The canopy blocks an observer from seeing the slot in the platform. The canopy includes a plurality of camouflaging elements positioned between the slot in the platform and the supported object, and the camouflaging elements are arranged in two or more layers.

Abstract: An artificial skin such as an outer covering or skin for an animatronic character. The skin may be formed by a method that includes providing a mold assembly with an exterior mold and a core. In the mold assembly, a cavity is formed between inner surfaces of the exterior mold and exterior surfaces of the core that defines the skin system. The mold assembly includes a seam-forming wall extending between the inner and exterior surfaces. The method includes inserting an elongate, tubular guide through holes in the seam-forming wall and pouring an elastomeric material into the mold to occupy the cavity between the exterior mold and the interior core. The method includes, after the material has hardened, cutting a seam in the skin system by cutting the material along the seam-forming wall. The tubular guide is separated into guide segments and a staggered joint is formed at the cut seam.

Abstract: A method for fabricating an artificial skin system for use with a robotics assembly. The method includes providing a mold core with an exterior surface defining an inner surface of a skin system, with this surface including a plurality of mounting elements. The method includes attaching, to each of the mounting elements, an elastomeric actuation piece or point (EAP). The mold core is positioned within an exterior skin mold, and a cavity is formed between the exterior surface of the mold core and inner surfaces of the exterior skin mold that defines topography and dimensions of the skin system. The method includes filling the cavity with skin-forming material. Then, after the skin-forming material hardens to form the skin system, the method includes removing the skin system from the mold core including detaching the EAPs from the mounting elements, and the EAPs are integrally bonded within the skin system.

Abstract: A method for fabricating a product, such as an animatronic character, with artificial skin. The method includes providing a mold assembly with an exterior mold and a core. In the mold assembly, a cavity is formed between inner surfaces of the exterior mold and exterior surfaces of the core that defines the skin system. The mold assembly includes a seam-forming wall extending between the inner and exterior surfaces. The method includes inserting an elongate, tubular guide through holes in the seam-forming wall and pouring an elastomeric material into the mold to occupy the cavity between the exterior mold and the interior core. The method includes, after the material has hardened to form the skin system, cutting a seam in the skin system by cutting the material along the seam-forming wall. The tubular guide is separated into guide segments and a staggered joint is formed at the cut seam.

Abstract: A computer-implemented method is provided for physical face cloning to generate a synthetic skin. Rather than attempt to reproduce the mechanical properties of biological tissue, an output-oriented approach is utilized that models the synthetic skin as an elastic material with isotropic and homogeneous properties (e.g., silicone rubber). The method includes capturing a plurality of expressive poses from a human subject and generating a computational model based on one or more material parameters of a material. In one embodiment, the computational model is a compressible neo-Hookean material model configured to simulate deformation behavior of the synthetic skin. The method further includes optimizing a shape geometry of the synthetic skin based on the computational model and the captured expressive poses. An optimization process is provided that varies the thickness of the synthetic skin based on a minimization of an elastic energy with respect to rest state positions of the synthetic skin.

Abstract: A method for fabricating a product, such as an animatronic character, with artificial skin. The method includes providing a mold assembly with an exterior mold and a core. In the mold assembly, a cavity is formed between inner surfaces of the exterior mold and exterior surfaces of the core that defines the skin system. The mold assembly includes a seam-forming wall extending between the inner and exterior surfaces. The method includes inserting an elongate, tubular guide through holes in the seam-forming wall and pouring an elastomeric material into the mold to occupy the cavity between the exterior mold and the interior core. The method includes, after the material has hardened to form the skin system, cutting a seam in the skin system by cutting the material along the seam-forming wall. The tubular guide is separated into guide segments and a staggered joint is formed at the cut seam.

Abstract: A method for fabricating an artificial skin system for use with a robotics assembly. The method includes providing a mold core with an exterior surface defining an inner surface of a skin system, with this surface including a plurality of mounting elements. The method includes attaching, to each of the mounting elements, an elastomeric actuation piece or point (EAP). The mold core is positioned within an exterior skin mold, and a cavity is formed between the exterior surface of the mold core and inner surfaces of the exterior skin mold that defines topography and dimensions of the skin system. The method includes filling the cavity with skin-forming material. Then, after the skin-forming material hardens to form the skin system, the method includes removing the skin system from the mold core including detaching the EAPs from the mounting elements, and the EAPs are integrally bonded within the skin system.

Abstract: A method for fabricating a product, such as an animatronic character, with artificial skin. The method includes providing data defining an exterior surface geometry of the product. A base geometry model of the product is generated based on the exterior surface geometry data, which in turn is used to fabricate a prototype of the product. Then, an exterior skin mold is formed using the product prototype mounted on an alignment block. The method includes fabricating an inner support structure based on the base geometry model having an exterior geometry smaller than the 3D base geometry model by the thickness of the exterior skin. The inner support structure is positioned within the mold with the inner support structure mounted upon the alignment block, which is received in the mold. The product is formed by pouring material for an exterior skin layer into the mold and over the inner support structure.