Animated Star Wars BB-8 Build - Simplified Design

FrightMaker

Well-Known Member

• Jul 4, 2016

• #1

Here's my version of a simple, animated BB-8 prop build. It doesn't roll, but it has a moving head, motion sensor, LEDs, and of course, sound. I took a look at paper mache options for crafting the spheres, arduino programming, and full 3D prints, but ended up focusing on a far simpler process using polycarbonate spheres, mechanical head motor, and home printed vinyl decals instead.

So let's get started!

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Last edited: Jul 7, 2016

FrightMaker

Well-Known Member

• Jul 4, 2016

• #2

Re: BB-8 Build (Non-Rolling) - Star Wars Dark Side of the Force Halloween

Step 1:

Using 2 polycarbonate spheres (Head: 300mm and Body: 500mm) made quick work of body fabrication. You can also choose to use paper mache over a ball or 3D print your body, but you can't beat the spheres for speed and simplification.

 

Last edited by a moderator: Nov 9, 2018

FrightMaker

Well-Known Member

• Jul 4, 2016

• #3

Re: BB-8 Build (Non-Rolling) - Star Wars Dark Side of the Force Halloween

Step 2:

The head needs to be 170mm tall and a simple holder for a pen at that height helps draw a cut line. Simply spin the sphere on a flat surface against the pen for the line.



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Step 3:

Cut the sphere along the line carefully with a rotary tool. The slower and more precise at this stage will minimize any sanding and filling later.



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Step 4:

Using pink foam from the hardware store, the beveled bottom of the head can be trimmed to size. Use two layers, one to fit snug in the head and another to be beveled.

 

Last edited by a moderator: Nov 9, 2018

FrightMaker

Well-Known Member

• Jul 4, 2016

• #4

Re: BB-8 Build (Non-Rolling) - Star Wars Dark Side of the Force Halloween

Coating the entire surface of foam in 2-part epoxy quickly seals it for painting.



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We're now starting to take the shape of BB-8! The body and head have been spray painted satin white in order to match. If you look closely at the movie stills, BB-8 is actually more of an ivory color than true white. However, it's easier to achieve that shade during the weathering process than matching it in spray paint cans.

 

Last edited by a moderator: Nov 9, 2018

FrightMaker

Well-Known Member

• Jul 7, 2016

• #5

Re: BB-8 Build (Non-Rolling) - Star Wars Dark Side of the Force Halloween

Step 5:

To make the eye, you can 3D print the parts or simply build one from craft foam. Check your dimensions and cut strips and glue them with epoxy.

 

Last edited by a moderator: Nov 9, 2018

FrightMaker

Well-Known Member

• Jul 7, 2016

• #6

Step 6:

Use a holiday craft ornament for the clear plastic for the eye.

 

Last edited by a moderator: Nov 9, 2018

towelkeeper

Well-Known Member

• Jul 8, 2016

• #7

Wow, your final result looks awesome... :eek
So many found parts. Amazing!

 

FrightMaker

Well-Known Member

• Jul 8, 2016

• #8

Thanks for the comment! I use a lot of recycled/repurposed items to keep costs down and simplify the design. Thanks for checking it out!

 

zv288bot

New Member

• Jul 9, 2016

• #9

Very cool!

Sent from my LGLS740 using Tapatalk

 

FrightMaker

Well-Known Member

• Jul 9, 2016

• #10

The remainder of the eye details are fabricated from foam, cardboard and wire.





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Since craft foam does not accept paint well, coat the entire eye assembly in epoxy. Once dry, spray paint mat black.

 

Last edited by a moderator: Nov 9, 2018

FrightMaker

Well-Known Member

• Jul 9, 2016

• #11

[h=3]Step 7:[/h]I considered drawing and masking off templates to pain the colored graphics, however, it proved much faster to draw effects on the computer using Photoshop and then printing them on 8.5"x11" vinyl sheets.

 

Last edited by a moderator: Nov 9, 2018

FrightMaker

Well-Known Member

• Jul 9, 2016

• #12

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While measuring each orange circle pattern (6 in total), a compass can help lightly score an outline circle to help align the stickers. Simply trim the graphics out of the sheet and carefully apply them.

 

Last edited by a moderator: Nov 9, 2018

FrightMaker

Well-Known Member

• Jul 9, 2016

• #13

Chartpak tape (1/32 or 1/64 thickness) helps make clean straight lines around the body and head. This tape can also work well to make smooth curves as well.

 

Last edited by a moderator: Nov 9, 2018

FrightMaker

Well-Known Member

• Jul 9, 2016

• #14

The chrome strip line around the head is started with black electrical tape.



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A strip of aluminum tape (trimmed shorter than the black electrical tape) is then wrapped around on top.

 

Last edited by a moderator: Nov 9, 2018

FrightMaker

Well-Known Member

• Jul 9, 2016

• #15

The top of the head is measured out and a compass is used to score two circles where the aluminum panels reside. Cut the strips of aluminum and place them on and use a sharp compass to score the edges to remove the scraps. A permanent marker makes quick work to color in the gaps.

 

Last edited by a moderator: Nov 9, 2018

FrightMaker

Well-Known Member

• Jul 9, 2016

• #16

 

CJ 617

Sr Member

• Jul 10, 2016

• #17

This is amazing, what a great build!!!

 

FrightMaker

Well-Known Member

• Jul 10, 2016

• #18

Hey Chris - thanks so much for checking it out!

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Ok - let's keep going!

[h=3]Step 8:[/h]The lighting effort began by using small LEDs being instered into small tatoo mixing cups. A holder fashioned from foam-core board was hot-glued together.






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In some cases, gluing multiple mixing cups together resulted in a more diffused color spread.

 

Last edited by a moderator: Nov 9, 2018

FrightMaker

Well-Known Member

• Jul 10, 2016

• #19

Aluminum foil tape was used to seal the wires and block any light bleed coming from cups. Lining the foam core holders with aluminum tape helps the light bounce around and make more of a soft glowing effect.



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The lights were all secured inside the sphere with hot glue.




In order for the light to shine through, the stickers needed to be cut and the white spray paint scratched off with a hobby blade.

 

Last edited by a moderator: Nov 9, 2018

FrightMaker

Well-Known Member

• Jul 10, 2016

• #20

Step 9:

BB-8 will be set up on a motion sensor and will light up, make noise, and turn his head while people walk by. Here's my simplified motion sensor build using a motion sensor, junction box (to house the connections) power strip, and extension cord.

 

Last edited by a moderator: Nov 9, 2018