This instructable was created in fulfillment of the project requirement of the Makecourse at the University of South Florida (www.makecourse.com).

This project is an animated figure of Cogsworth from Disney’s Beauty and the Beast. I began this project to learn more about designing animatronics, and the program required to bring them to life. For this design, I wanted to develop a program that would allow Cogsworth to wiggle back and forth every hour (the same number as the hour), and finish with a bow. I developed several concepts and design variations that would allow him to accomplish this movement. Once I believed my design was complete, I began to 3D print and test each part to finalize my design. Ultimately, this assembly utilizes a total of 22 3D printed parts. Throughout the design process, I also developed a C++ code to communicate with 5 servo motors using an Arduino.

This instructable will go through how to build, assemble, and program this animatronic. Along with this I will give helpful tips on where this design can be improved or modified in the future.

Cogsworth Animatronic
Download

Step 1: Tools, Parts, and Materials

3D printer
- Disclaimer: Some parts are as wide as 9" x 9", therefore a large bed is required
Wood Filament
Battery Supply (I used a portable phone battery)
Arduino Board
Bread Board
Clock Features
Aluminum Wire
Screws
Screw Driver
Door Hinge
X-Acto Knife
Adhesive
Paint Brush
Paint & Wood Stain
Servos
- 2 of Pitsco Education 39197 180 Standard-Scale HS-485HB Servo Motor
- 4Pcs SG90 9g Micro Servos for RC Robot Helicopter Airplane Controls Car Boat

Step 2: Raw CAD Files

Step 3: 3D Printing Parts

Print items 1 though 18 from the bill of materials.

I would recommend printing in the same order as the Bill of Materials in order to begin working with the code early on.

Step 4: Sand and Paint Parts

For the best finish, sand and paint each print.

These are the colors I used to replicate Cogsworth:

Wood Stains:

Red Oak (majority of exterior)
Black Cherry (internal belly and mouth)
Golden Pecan (face)

Paints:

Gold
Fire Opal (tongue)
Ink Blue (eyes)
Snowball (eyes)
Black (eyebrows)

Step 5: Assemble the Base

Adhere each "Foot" to the "Waist" by using adhesive and aligning each hole.
Secure the power supply within the base of the "Waist"
- Note: This could be located within the belly for easy accessibility. I placed it at the base to limit the amount of weight the base servo supported.
Secure the small gear onto the base servo motor.
Secure the servo into the waist using adhesive or screws by placing the servo into the designated notch.
Screw the "Gear on Belly" onto the "Belly". Verify that the edge of the gear does not exceed the edge of the belly to ensure that fewer errors later on.

Step 6: Assemble Both Hands

Screw and secure the large servo motor onto the edge of the shoulder.
Hook the aluminum wire through the small hole produced in the hand.
Hook and secure the aluminum wire onto the servo motor. Adjust the length of the wire to fit within the shoulder.
Insert the servo motor and hand into the arm. Adjust the Aluminum wire as necessary until functioning properly.
Secure the small servo motor inside the shoulder.
Connect and secure the top of the shoulder. Verify that this is attached securely and is easily detachable.
Mount hand onto the "Belly to Back" by sliding into its designated slot. Verify that the internal wire is place through its specific notch to avoid unplugging wires.
Repeat until both hands are assembled.

Step 7: Assemble Belly

Using small door hinges, align and attach the "Door" to the "Belly".
Attach the "Ticker" to the "Belly". Verify that the "Ticker" is able to move on its own from gravity.
Attach and secure the "Belly" to the "Belly to Back" utilizing the notches on either side.
Place the "Belly" onto the "Waist" by aligning the groove on the base of the "Belly" to the notch on the "Waist".

Step 8: Assemble Head

Secure the "Nose" onto the "Face"
- Note: Depending on the clock features ordered, the "Nose" hole diameter may need to be adjusted.
Assemble the clock parts through the "Nose" as instructed by the clock purchased.
Mount and adhere the "Face" to the "Head".
Secure the "Head" onto the belly.

Step 9: Wiring Cogsworth

Wire each servo as shown in the fritzing diagram. Each servo motor is connected to the same 5V power source, ground, and its corresponding input pin.

For this Code:

Input 5: Right Shoulder

Input 6: Left Shoulder

Input 7: Right Elbow

Input 8: Left Elbow

Input 9: Waist

Step 10: Downloading and Updating Code

Download this Arduino Code and link to your Arduino Board. After testing is complete, a larger delay will need to be added in the code to wait an hour before running the next iteration.