LEGO Animatronics
As a technical designer for Merlin Entertainments, I create animatronics to bring LEGO models to life in worldwide LEGOLAND Resorts and LEGO Discovery Centres.
The range of project briefs and ownership of seeing animatronics through from design to installation has made me a multi-faceted designer. In my role I have proficiency and experience using Fusion 360, Autodesk Inventor, Rhino, Arduino Programming, PLC troubleshooting, practical electronic skills, 3D printing, and CNC machining.
I have also improved my budget and production planning skills by managing simultaneous project workloads; sourcing components from suppliers; completing documentation to company standards; and ensuring effects are fully tested before delivery.
LEGO Discovery Centre
Here I was tasked to bring a fantasy construction scene to life, which showcases LEGO Technic products.
Four effects I designed, built, tested, and installed for the construction scene.
Design Process
Sketched concept proposals were developed into 3D models of the animatronics and their respective 2D manufacturing drawings using Fusion 360. Designs were reviewed multiple times along development, as to ensure the initial brief was met and effects would run reliably. I utilised 3D printing and CNC machining to create frames for the mechanisms as to increase speed of manufacture, lower production costs, and improve ease of assembly.
Similarly, slotted holes were implemented to allow adjustment of the animatronics height to fit the LEGO models and belt tension of pulley mechanisms. Using dog bone tail joints further allowed effects to be built fully in-house as aluminium panels could be CNC’d and fastened together with screws.
The Rolling Road and Crane Animations at the end of install. The effects are dressed with LEGO minifigures to tell the story of the construction scene.
The 3D model of a Rolling Road effect. The chain belt 'road' is driven by three sprockets sandwiched between two aluminium mounting plates.
The assembled Rolling Road effect. A jig was created to drill identical holes in the acetal belt, allow LEGO elements to be screwed down.
A front view of the installed Rolling Road - where the suspension of the LEGO tyre is tested by the chain belt passing underneath it.
The 3D model of the Crane effect. Pulleys and a toothed belt drive the crane from each end with its positioned confirmed by inductive sensors.
Testing the Crane effect in the workshop. The Crane could only be driven on one side due to its allocated podium space, hence LEGO was reinforced to prevent dragging.
The Engine and Gearbox animations at the end of install. Designing a 3D printed coupling between the motors and LEGO allows the animations to appear to be driven by LEGO only, increasing the interest in Technic products.
The 3D model of an Engine effect. A 3D printed coupling allows the motor to drive LEGO elements directly.
The Engine effect during build. 3D printing enabled a quick assembly, fewer parts, thus reduction in manufacturing costs.
The 3D model of the Gearbox effect - utilising the same mechanism and mounting plates as the Engine effect to reduce costs.
The Gearbox is triggered by an interactive push button to allow the guests to change gear and watch the LEGO tyre change speed. Interest in LEGO Technic is encouraged as guests can watch the gear change mechanism happen as they trigger the effect.
Walkthrough of the final construction scene, highlighting the interactive element of the Gear Box effect.
Installation
I have experience of working overseas on install for a total of 6 weeks. Tasks included running cabling and wiring control cabinets as to power all effects and light all LEGO models; working at height to install animatronics; and problem solving effects and the PLC program to get effects running as intended.
Adaptability, electrical skills and leadership therefore improved by directing and overseeing contractors, and being responsible for the wiring and testing of all effects.
Lighting and animatronics that I installed and troubleshot to run as intended.