Character line out

Above is a large picture (click image to view full size) of the characters featured in our film. These four character marquettes were sculpted and digitally painted by Josh and Myself. In the center are our main characters that I posted earlier in this blog, Link , Roy the Mail Man and the Actress named Elle. To the left is the Theater Usher. This is a bad tempered character who's only goal is to throw Roy out of the theater. He's a large square character who fills a doorway and is Roy's greatest obstacle. To the right of the image is the little Old Lady who plays a small part in the story. She's a very short and colourful character who's part in the film mostly consists of her staring lovingly at the Mail Man. You can find information on the development of these characters Here.

Armature Construction

Using the my armature design drawings I decided to make a test version of the 'Mail Man' armature. I was able use this armature in my 'Mime Project' to test if it works OK. This was the first time I would be using the silicone hands that I made and my new home made ball and socket joints at the neck. 

I started by cutting all the K&S square brass tubing and aluminium tubing I would be needing. I used my diagram to make sure all the pieces were the correct length. Next I twisted and cut all the Aluminium wire, using 3x twist for the legs and spine and 2x twist for the arms. I used heat shrink tubing around the wire to protect it from the sharp edges of the tubing. This means that the wire should last longer before eventually breaking.

I used epoxy resin to glue all the parts together making sure everything was the correct length and symmetrical. Instead of making new feet I recycled some from an old puppet I made in my second year at Uni.

In the picture above you can see the armature fully assembled with the new hands. I used white milliput (epoxy putty) to strengthen some areas. The milliput on the neck is what I will use as the core of the head.

Finally I bulked out the chest and waist using blue foam that I carved into shape. I cut out a square channel in the foam to give access to the rig point in the waist. The next step will be to continue bulking out the figure using sponge.

Armature designs

Before I start making the puppets for each character I draw a 1:1 scale plan of the armature. It's important to design the armature to ensure that the character will have the correct proportions and so that it'll be strong enough the support the puppet.

Below are my plans for the Mail Man (Roy) and the Actress (Elle). In each drawing I included the outline shape so I can see how the armature fits inside.

 

I decided to make the puppets from a mix of Aluminium wire and Ball and socket joints. I've made many different wire armatures in the past and know that they should work effectively in this project and keep costs down. Each part will be replaceable in case of damage thanks to the Interchangeable K&S sections. The puppets will have rig points at the waists for if they require external support. I will be using nut and bolt tie downs with feet made out of steel plate. Also each hand has a nut rig point in the palm to allow props to be tied in place.

I will be manufacturing my own ball and socket joints for the puppets necks. I feel that the head is the most important part of a puppet as that's where most attention is directed. Ball and socket joints give smoother movements that wire armatures and therefor give better performances.

The other characters will use similar armature plans but designed with various different proportions.