Lifelike Robotic Head Prototype
Materials used PLA (3D printing), car filler, ease release, sandpaper (80/150/240/320/400), Smooth-On silicone, hot glue, M10 bolts, wood blocks & vices
Objective During the Spring 2025 semester, I worked as an undergraduate researcher for the Fluid Interfaces group at the MIT Media Lab, assisting in the development of a lifelike robotic head prototype modeled after the InMoov Head i2. My work involved crafting and molding silicone skin, performing mechanical repairs, and conducting electrical testing to ensure the prototype functioned reliably. I collaborated closely with the research team to refine the head’s features and performance, making it suitable for a study investigating human reactions to the uncanny valley. Through this project, I gained hands-on experience in robotics fabrication, learned new technical skills, and contributed to research that combined design, engineering, and human-computer interaction.
The Process
All mold parts were 3D printed with 15% infill, 2 mm wall thickness, tree supports, and brim adhesion. Once printed, the two outer mold pieces were sanded and sprayed separately to achieve smoothness and remove visible layer lines. Car filler was applied between sanding cycles using 80, 150, 240, 320, and 400 grit sandpaper, with finer grits and lighter sprays used toward the end to avoid drips. The process ensured a seamless transition between the two outer pieces and a smooth interior surface, preparing the mold for silicone pouring.
The Process Silicone layers were poured into the outer mold to form the face without the use of inner molds. Ease release was sprayed onto all surfaces before pouring. Smooth-On Ecoflex 00-10 silicone was mixed and poured in at least four coats, each cured for three hours before the next. The mold was rotated during pouring to ensure even distribution and coverage of details. Facial features such as the eyes and ears were fully submerged to prevent tearing or incomplete formation.