Make: Volume 90

Once this system was tested and final assembly

was complete, we used 1½"-thick L200 EVA foam

to create the “ribs” that would fill out the body

shape under Bruce’s fur (Figure

K

). The profiles

for these shapes were made in Autodesk Fusion

360, and exported as flat SVGs at full scale, so they

could be traced onto foam for bandsaw cutting.

The skull and jaw shells were made with

fiberglass and standard laminating resin, molded

off of the same taxidermy form we used for the

digital scan (Figure

L

). Fiberglass is commonly

used for animatronic shells due to its compliant

rigidity and relatively low weight. 3D-printed

antlers (Figure

M

) were affixed ...