Disney Research in Zurich, Switzerland, has developed a new process called ‘Physical Face Cloning’ that allows it to create realistic animatronic characters. The technology scans the head of a human before putting the coordinates and expressions into a 3D program. Measurements such as elasticity of the skin, and skin thickness, are then used to produce a 3D printed mold of the face before a silicon layer resembling syntheic skin is then attached. The result is a realistic-looking robotic head with accurate expressions and features such as wrinkles.

Disney would only be using the technology and process to produce life-like animatronic figures in its theme parks to add to the realism of the interactive characters. Watch the video below to see what the process involves:

Disney Research

Image courtesy of Express Monorail