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 method for fabricating a product, such as an amimatronic 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: An artificial skin system for use with a robotic assembly such as to provide an animated robot head with realistic skin movement. The skin system includes a receiving component for contacting the manipulator mechanism of the robotic assembly and also includes an exterior skin component that extends over the receiving component. An inner surface of the exterior skin component is integrally bonded to the receiving component such that the exterior skin component moves with the receiving component when a manipulator mechanism or robotics anchored to the receiving component moves or applies a force. The exterior skin component is formed of an elastic material with a second hardness that differs from a first hardness of elastic material of the receiving component, e.g., is less than the first hardness. The skin system includes a backing component bonded to the other components with a third hardness less than the first and second hardnesses.

Abstract: A method for fabricating a product, such as an amimatronic 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 method for fabricating a product, such as an amimatronic 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: An artificial skin system for use with a robotic assembly such as to provide an animated robot head with realistic skin movement. The skin system includes a receiving component for contacting the manipulator mechanism of the robotic assembly and also includes an exterior skin component that extends over the receiving component. An inner surface of the exterior skin component is integrally bonded to the receiving component such that the exterior skin component moves with the receiving component when a manipulator mechanism or robotics anchored to the receiving component moves or applies a force. The exterior skin component is formed of an elastic material with a second hardness that differs from a first hardness of elastic material of the receiving component, e.g., is less than the first hardness. The skin system includes a backing component bonded to the other components with a third hardness less than the first and second hardnesses.