Big Robot Exhibit

This robot stands 14' tall and could be very intimidating to children visiting the museum.  We wanted this exhibit to draw kids in and therefore the robot needed a friendly and welcoming face.  We took our cues from Yoshi, but worked through the design process from drawings, digital models, foamcoare mockups and finally this mixed media result.  Primarily plywood, it also has many 3D printed elements including light up googly eyes and a camera that allows kids to see what the robot sees.  We even made a mechanism inside the robot that kids can use to puppeteer the head, panning around the room.

The robot exhibit was designed to have a variety of interactive elements that ranged from collaborative gamification to a busy board.  Pictured here is a deceptively simple circuit board that was designed for younger children.  It is a magnetized matching activity.  The shapes were molded then cast in a tinted semi-rigid rubber, with a rare earth magnet embedded.  The circuitry play board has matching shaped sockets with magnets that will either attract the match or repel the wrong plug, challenging the children while having fun.

Big robots need big batteries.  One of the interactive components has a pair of 12" tall copper​-looking batteries.  When placed correctly in the battery boxes on the robot's legs, the embedded magnets snap the battery into place and allow the kids to activate the illuminated power button.

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We learned that the large 3D printed batteries, while functioning properly and looking realistic, were having some problems a few months after the exhibit opened.  The kids were playing hard with them, causing the batteries to take some damage.  We started iterating on the design and with our extensive experience in mold-making and casting materials, we came up with lasting solution.  We molded an original 3D printed battery and cast the new batteries in a urethane rubber.  Using copper powder, we were able to make them look great, function within the activity (due to embedded magnets in casting) and be durable!  They can be dropped or get knocked around and never scratch or dent again.  It's always fun to see someone to be surprised to discover they're squishy!

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In the robot control room, kids can have all kinds of fun and maybe even learn a thing or two.  Across the dash are three separate elements for controlling the robot, figuring out a scavenger hunt type of puzzle to power on the robot, and a learning activity about using solar panels.  Additionally, the control room gives children the unique opportunity to puppeteer the robot's head, panning around and through the monitor see what the robot sees.  A busy board on the left offers fidgets, levers, buttons and switches, many of which create sounds and lights.

The control area of the robot (as detailed above) wouldn't be any good if the children couldn't get up to it!  Inside the robot is a robust steel frame, anchored to the museum floor.  The control room is on a platform of steel and plywood that is five feet off the floor.

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While keeping in mind safety and accessibility, we designed and fabricated a custom staircase that looks appropriate for a robot repair station.  Due to existing features on site, we determined the stairs would have to be made with a landing and ninety degree turn.  With help from one of our frequent collaborators, Smyth Metalworks, we made railings that were safe, durable and accented with the several of the sponsors brand colors.