Here's how to build simple animatronics using inexpensive hobby servos and the MAKE controller kit. I wanted to keep this as simple as possible so there is no programming required and the electronics are kept to a minimum so that anyone should be able to do this with a minimum of tools and experience.
I wanted to create a animatronic head for a costume I'm constructing. I wanted it to be entirely self contained- no exposed wires, etc. and unlike many animatronics used in movies, I didn't want to use radio control due to complexity/control issues. I also couldn't afford a commercial animatronics controller.
Enter the MAKE controller! This piece of hardware allows you to connect readily available hobby servos (as well as motors, lights, etc.) to simple analog input devices (I'm using flex sensors) to control movements. I have this set up running the controller in POLY mode, which doesn't require any computer programming and is very easy to configure. Of course you can always program the controller later on to maximize its potential- it's a pretty amazing piece of hardware.
Here's what the finished animatronic armature looks like (it's mounted to an old welding helmet as a test rig) along with a movie clip and what the finished costume will look like- it's a Horus guard from Stargate.
Here's a video of it working-
There are a ton of possibilities using this controller for animatronics:
Make a Predator costume with animatronic head and shoulder cannon
Build a giant dinosaur with a moveable head, eyes and tail that reacts to movements or goes through a pre programmed routine
Create interactive displays and haunted house attractions
Follow along and I'll show how the mechanism for the Horus head is constructed and maybe you'll be inspired to create your own animatronics....
UPDATE: Makingthings.com, the manufacturer of the MAKE controller has removed the POLY mode firmware necessary for this instructable from their website and it no longer is included in the firmware for the controller. If I can find an earlier version of the firmware necessary I'll post it here. They have also removed all tutorials regarding the POLY functions. Bummer. I have started working with the Arduino platform due to it's lower cost, smaller size and ease of use and have created another animatronics tutorial here:http://www.instructables.com/id/Arduino-animatronics-make-your-awesome-costumes-m/