Project Overview
I'm excited to share my ongoing project: a full-scale, fully animatronic Wall-E replica from Pixar's 2007 film. This build features complete articulation of the head, neck, arms, body, and track system, authentically recreating the character's movements and personality as seen in the film.
I started this project in 2019 and have since refined the design through multiple iterations to achieve the level of mechanical sophistication and reliability required for a traveling animatronic display. I've been documenting the build process on YouTube for those interested in seeing the fabrication and assembly work in detail.
Design Philosophy: Modular Architecture
The core principle driving this build is modularity. Wall-E is designed to break down into discrete subsystems that pack into Pelican cases for transport to conventions, events, and demonstrations. This constraint has influenced every design decision, from structural interfaces to cable management.
Key subsystems include:
- Body chassis with integrated electronics
- Head and neck assembly
- Left and right arm assemblies
- Left and right track assemblies with suspension
Electronics and control systems
Each module uses specific mating geometries (register fits, locating bosses, and recessed interfaces) for self-alignment during assembly. This eliminates the need for separate alignment pins while maintaining repeatability across multiple assembly/disassembly cycles. Connection points use vibration-resistant fasteners to ensure structural integrity during operation.
Structural Approach: Hybrid Construction
The build employs a hybrid construction method that balances strength, weight, and manufacturability:
Aluminum Framework:
- 1/8" and 1/4" 6061 aluminum plate, primarily laser cut
- Plates connected with standoffs and tapped mounting points
- Secondary operations (countersinking, tapping) are done in-house to manage costs
- Design work done entirely in metric using SolidWorks
3D Printed Components:
- Cosmetic shells and detail parts
- Non-structural brackets and housings
Complex organic shapes that would be impractical to machine
Custom CNC Parts: The most significant design decision was investing in custom CNC components for critical mechanisms, particularly in the head and neck assemblies. Rather than using off-the-shelf brackets, spacers, and adapters, I designed integrated parts that eliminate hardware and reduce part count.
For example, the head tilt mechanism uses a single custom bearing plate that integrates mounting surfaces, bearing seats, and structural elements that would otherwise require multiple stacked components and dozens of additional fasteners. This approach is more expensive upfront, but results in lighter weight, better alignment, fewer failure points, and significantly simplified assembly.
Neck Mechanism: Three-Axis Motion System
The neck assembly demonstrates the integration of custom parts with commercial components:
- Pan/Rotation: Base-mounted motor provides 360° rotation capability
- Linear Extension: Commercial linear actuator provides vertical neck extension/retraction, one of Wall-E's most characteristic movements
- Head Tilt: Custom CNC'd bearing plate at the top enables head pitch articulation
This three-axis system recreates Wall-E's full range of expressive head movements while maintaining a compact package that interfaces cleanly with both the body chassis below and the head assembly above.
Current Build Status
Completed:
- Main body chassis (aluminum framework with mounting points for all subsystems)
Head and neck mechanism (full range of motion validated)
- Cosmetic panels and detailing
In Progress:
Arm assemblies (currently prepping parts for assembly)
- Arms are primarily 3D printed; future revision may incorporate a lightweight metal chassis for improved rigidity
- Electronics integration and control systems
In Design:
- Track assemblies and drivetrain system
Manufacturing Workflow
- CAD: SolidWorks (all design work in metric)
- Laser cutting: DXF exports for 2D plate work
- CNC machining: STEP file exports for 3D custom parts
- 3D printing: FDM for cosmetic and non-structural components
- Assembly: Primarily socket head cap screws with vibration-resistant fastening methods
Next Steps
The immediate focus is on completing the arm assemblies and finalizing the electronics integration throughout the system. Following that, I'll be working on the track assembly design and drivetrain implementation to enable mobility.
Once all subsystems are complete, final integration testing will validate the modular assembly process and overall system performance.
I'm planning to post quarterly updates as significant milestones are reached. Looking forward to sharing the continued progress with the community and hearing feedback from fellow engineers and makers!
For those interested in more detailed build documentation, I'm maintaining a YouTube build log showing the fabrication and assembly process: https://www.youtube.com/watch?v=--tsIsTRB0w&t=1s
All design work was done in SolidWorks. CAD images shown represent the current design state.
