How to Make Super-Sized Animatronic Dinosaurs

Using a 16-Meter Long, 8-Meter High Tyrannosaurus Rex as an Example

While utilizing the sponge and silicone process, the creation of super-sized animatronic dinosaurs differs from that of regular large-scale ones. When we mention ‘super-sized,’ it generally refers to models exceeding 10 meters in length or 2.7 meters in height. These colossal dinosaur models need to be assembled in segments, encompassing various body parts and limbs. Certain long-necked dinosaurs also require segmented construction in their necks. This is primarily for two reasons: ease of production and convenient transportation via trucks. Next, let’s delve into the production process using a 16-meter-long, 8-meter-high Tyrannosaurus Rex as an example.

Here are 8 steps explaining how to create a super-sized animatronic dinosaur model. You can click on the links below to quickly jump to specific sections.

Step 1.Welding the Dinosaur’s Basic Frame

1.The welder first constructs the mainframe, primarily comprising the Tyrannosaurus Rex’s two hind legs and the initial torso, connecting the hind legs to the base using flanges for easy disassembly and installation.
2.The torso framework is detached from the hind legs, and flanges are welded at the separation points to enable subsequent reconnection. Additionally, two more flanges are welded onto the base to connect and secure the torso framework to the base.
3.Welding the complete torso of the dinosaur involves the head, neck, tail, and other parts. Mechanisms for movement are crafted at the joints that require mobility, with power devices such as motors and reducers being installed. Typical movements include blinking, mouth opening, head tilting, front limb motion, and tail swinging.

Step 2.Assembling Control Circuits and Testing Movements

Connect all the devices inside the dinosaur to the circuit, link them to the motion debugger, then power it on to test if all the movements work correctly.

Assembling Control Circuits and Testing Movements

Step 3.Sponge Modeling

Wrap high-density sponge around the steel frame of the body to fill the dinosaur’s muscles. Craftsmen will individually cover different parts of the dinosaur with sponges of varying densities, followed by sculpting the sponge using specialized tools.

Sponge Modeling

Step 4. Creating Skin Texture

Workers use a soldering iron to create patterns on the sponge, following the texture design from the reference image. This method helps create realistic textures with varying depths and shapes, giving the dinosaur a lifelike appearance.

Creating Skin Texture

Step 5. Creating Dinosaur Skin

After creating textures on the foam surface, workers apply a layer of nylon fabric and evenly spread silicone gel. This enhances the model’s skin for better durability and flexibility. Repeatedly applying silicone gel 3 to 4 times ensures a certain thickness and strength. Once completed, the model’s skin becomes soft and elastic.

Step 6. Painting

Apply water-based paint to color the dinosaur’s body. After painting, add another layer of silicone gel as a protective coating. This prevents the model from fading due to friction or long-term exposure to sunlight and rain.


Step 7. Assembly and Rear Leg Production

1.After completing the dinosaur’s torso, use a hoist to suspend it and reassemble the rear legs to form the complete dinosaur frame.
2.Following the above process, proceed to sculpt the foam, iron the texture, apply silicone skin, and paint the rear legs.

Step 8. Action Testing and Adjustment

Based on the client’s preferences, set the sequence and repetition of the dinosaur’s movements. Adjust the timing and speed of each action to ensure a more natural and coordinated overall motion for the dinosaur.

Action Testing and Adjustment

After this meticulous and intricate series of steps, a lifelike 16-meter-long, 8-meter-high lifelike Tyrannosaurus Rex is completed. If you’re interested in our product, please feel free to contact us. We’ll be delighted to offer you our professional customization services.