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Animatronic Skeletal Monster

16ft Animatronic Super Creature

John Merk

This large animatronic creature is 16 feet tall and has a complete welded steel armature. His 9 movements are controlled via computer and all components are installed inside the creature.

large animatronic foam monster

Animatronic EPS foam monster arm

His body is made of 2-pound foam.
The main foam blocks were cut with Hot Wire Foam Factory’s 4-Foot Compound Bow Cutter.

Animatronic EPS foam monster

The foam was then channeled out to fit onto the steel framing with Hot Wire Foam Factory’s Industrial 10″ Hot Knife with the Sled Guide.

Once glued to the frame, I sculpted the rest almost entirely using the edge of the Hot Knife. I even put the wrinkles in his skin using the Hot Knife.

large animatronic foam monster

To smooth off and round the edges I used a horse brush.

He was then coated in multiple layers of rubber latex and painted.


Suggested tools/materials for this project:

4-Foot Bow Cutter • Industrial Hot Knife Kit