Animatronic Fabrication Notes: Atlantic Bottle-Nosed Dolphin

This is full-sized, adult, Atlantic Bottle-nosed Dolphin replica with pneumatic actuators controlled by a simple foot switch. This was part of a live show where they roll this out to teach the visitors a few things about dolphins.

This animatronic dolphin project began by pulling out a set of molds. These dolphin molds were originally created for the film, “Flipper”.

In this post, behind the scenes imagery and descriptions are shown from a build featuring a full-sized Pacific Dolphin (approx 8’ long).

Dolphin Mold Set Assembled

This is the assembled dolphin mold set. It’s laying on it’s back because the sprues are located along the belly.

Dolphin Core Mold

Dolphin exterior mold set assembled with the animation core installed.

These images show how a large mold is used to create an animation core as well as a perfect thickness, silicone skin.