Mechanical Engineering
Tagline
Safety With Character
Year
2026
Sponsor
Disney Imagineering

Our project, Charapace, aims to design a purely mechanical, pinch-free shell system for an animatronic carnivorous plant mounted on a Dynamixel OpenManipulator-X robotic arm. The goal of the project is to improve safety in human-interacting robotics by reducing pinch points where fingers, body parts, or loose clothing could become trapped during operation, while still maintaining an immersive and expressive animatronic appearance. Current robotic systems often expose moving joints and mechanisms that may create hazardous gaps during motion. Our design addresses these concerns through the development of protective shell geometries and compliant joint coverings integrated into the robotic arm structure. The project development process included research into existing robotic safety methods, brainstorming multiple design concepts, and prototyping solutions for critical pinch-point regions such as the jaw, wrist, elbow, and shoulder joints. Prototype shell components were developed and mounted onto a mockup puppet arm, and an electronics control system was implemented to support animation and motion control. The resulting system demonstrates a safer approach to animatronic design that prioritizes both user interaction and functional robotic movement for close-proximity environments such as entertainment and themed experiences.

Students

Mechanical Engineering
Mechanical Engineering
Mechanical Engineering
Mechanical Engineering
Mechanical Engineering