Animatronic Head V3

Animatronic Head V3 is a fully 3D printable robotic head designed for makers, students, and robotics enthusiasts. Powered by an ESP32 XIAO, it uses 10 servos to animate the eyes, eyelids, eyebrows, smile, jaw, and neck. The design is modular and intended as a platform for animatronics, robotics, and AI integration.

*All components can be found on Amazon for roughly $50 and the prints take less than half a roll of filament

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Bill of Materials (BOM)

Electronics

• 7 × MG90S micro servos

• 3 × MG996R high torque servos

• 1 × Seeed Studio XIAO ESP32 microcontroller

Fasteners

• 58 × M3 × 10 mm screws

• 6 × M3 × 16 mm screws

• 2 × M3 × 25 mm screws

• 64 × M3 hex nuts

Recommended

• 5 V, 8 to 10 A regulated power supply

• USB-C cable for programming

• Jumper wires

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Assembly Guide

The head is designed to be assembled from the inside out. Following this order keeps every fastener accessible and makes assembly significantly easier. Test each mechanism as you build before moving on to the next step.

The assembly files can also be found below to assist in your build.

Step 1: Assemble the Eyes

1. Screw the pupils into the eyeballs.

2. Attach the upper eye connector to each eyeball.

3. Assemble and install the upper and lower eyelids.

4. Install the center eye servo into the lower eye connector.

5. Attach the lower eye connector to the eyeballs.

6. Insert the longer M3 screws through the top of the eyeballs to connect the upper and lower linkages.

Verify that both eyes and eyelids move smoothly.

Step 2: Mount the Eye Assembly

1. Position the completed eye assembly onto the eye plate.

2. Secure it using the lower eyelid holders.

3. Confirm that nothing binds during movement.

   

Step 3: Assemble the Eyebrows

1. Install the servo linkages onto each eyebrow servo.

2. Mount the servos to the eyebrow plate.

3. Connect the eyebrow linkage arms.

4. Test the eyebrow movement before installation.

   

Step 4: Build the Upper Assembly

1. Attach the upper and lower spacers to the eye plate.

2. Install the eyebrow assembly onto the eye plate.

3. Verify that the eyebrow mechanism moves freely without contacting the eye mechanism.

   

Step 5: Assemble the Jaw

1. Build the smile mechanism and attach it to the jaw plate.

2. Install the jaw servo.

3. Mount the completed jaw assembly beneath the eye plate using the lower spacers.

4. Test the jaw and smile mechanism before continuing.

Step 6: Install the Teeth

Attach the upper and lower teeth, making sure they do not interfere with jaw movement.

Step 7: Install the Outer Shell

Once every mechanism has been tested and the electronics are functioning correctly, install the remaining skin and cosmetic panels. These parts are installed last because they block access to many internal fasteners.

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Wiring

Connect all servos to individual GPIO pins on the Seeed Studio XIAO ESP32. Power the servos from an external 5 V supply, not directly from the ESP32. 

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Final Checks

Before powering on the head:

• Tighten all fasteners.

• Verify every linkage moves freely.

• Ensure no wires can be pinched by moving parts.

• Test each servo individually before running the complete animation sequence.

• Calibrate servo center positions before installing any remaining cosmetic panels.

If you build one, I'd love to see your results. Feel free to share photos, videos, or improvements with the community!