Abstract: An exoskeleton to support and move a large character costume and to transfer weight of the costume away from a performer's body. The exoskeleton includes a spine including an elongated and rigid vertical member and also includes a waist ring configured to extend about a waist of a performer using the exoskeleton in a spaced apart manner. A lower end of the spine is attached to a rear center portion of the waist ring. The exoskeleton includes a pair of leg assemblies each pivotally coupled on opposite sides of the waist ring. Each of the leg assemblies is spaced apart from a leg of the performer and extends below a foot of the performer, whereby weight is transmitted to a support surface. Each of the leg assemblies may include at least one passive assist mechanism configured to assist the performer in moving the exoskeleton with bipedal locomotion.

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: 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 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 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 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: In one aspect, a supported walking system is disclosed, comprising a robotic walking figure and a wheeled support that at least partially supports the robotic walking figure. The supported walking system may be driven and controlled by a human operator. Computer algorithms automatically control the robot's walking functions so that it may step forwards, backwards, and sideways in synchronicity with the movements of the cart while driving and turning at varying speeds.

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 robotic joint configured as a 3-axis joint configured with a shoulder or other human joint form factor. The joint includes a first link made up of a block attaching to a torso and a stationary electric actuator assembly mounted to the block. A second link is connected to the first link to rotate about a first axis and be driven by the actuator assembly. A third link is attached to the second link to rotate about a second axis orthogonal to the first axis when the third link is driven by the actuator assembly. A fourth link is connected to the third link to rotate about a third axis orthogonal to the second axis when the fourth link is driven by the actuator assembly. The actuator assembly includes three electric motors with threaded drive capstans driving pulleys in the links while being spaced apart from the rotating links.

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 robotic joint configured as a 3-axis joint configured with a shoulder or other human joint form factor. The joint includes a first link made up of a block attaching to a torso and a stationary electric actuator assembly mounted to the block. A second link is connected to the first link to rotate about a first axis and be driven by the actuator assembly. A third link is attached to the second link to rotate about a second axis orthogonal to the first axis when the third link is driven by the actuator assembly. A fourth link is connected to the third link to rotate about a third axis orthogonal to the second axis when the fourth link is driven by the actuator assembly. The actuator assembly includes three electric motors with threaded drive capstans driving pulleys in the links while being spaced apart from the rotating links.

Abstract: A system for creating a flickering effect comprising a simulated candle housing, a light communicating channel on the housing, a source of ultraviolet light disposed in the channel, and a simulated flame having ultraviolet material thereon movable back and forth from its vertical axis mounted in the housing, the light focused on the simulated flame simulating a flickering flame.

Abstract: In one aspect, a supported walking system is disclosed, comprising a robotic walking figure and a wheeled support that at least partially supports the robotic walking figure. The supported walking system may be driven and controlled by a human operator. Computer algorithms automatically control the robot's walking functions so that it may step forwards, backwards, and sideways in synchronicity with the movements of the cart while driving and turning at varying speeds.

Abstract: A system for creating a flickering effect comprises a light communicating cable, at least one light receiving cable secured on a rotatable mount rotatable about a horizontal axis, a light diffuser element in communication with the at least one light receiving cable and a rod connected to the diffuser element for causing rotary motion of the light diffuser surface about the horizontal axis.