Animatronic Zombie Build

A friend and I had the idea to create a robotic zombie head mount.   I've always wanted to make an animatronic human, so I though this would be a great way to try this.

First I design the entire mechanism in 3d software:

One thing I wanted to get right was the jaw motion, jaws don't just flap on a simple hinge, at the mouth open the jaw swings forward--I created a mechanism that reproduced that motion:

3D printed version 1.0

I decide to use VSA animatronic software: https://www.brookshiresoftware.com/vsa_overview.htm

This program allows you to import text files to drive the animation.  I take advantage of this and create a rig with expressions in Maya that allows me to animate on the computer and export that animation to VSA to be played back on the animatronic head.  It works pretty well as long as I avoid quick motions that the servos can't keep up with. 

Two versions of the skull, the one on the left is the starting framework for the sculpted positive that will be used to create the rubber skin for the puppet:

I use clay to create the positive:

Mold has been made and ultra-cal version of positive is finished, this will be the foundation for the sculpted zombie:  

 

3d printed some teeth, they fit in the jaw structure perfectly:

Update:  I really disliked the neck and eyelid design, which prompted me to redesign and reprint to version 2.0.

Here's a a singing skull another maker made from the files I uploaded on thingiverse:

Yet another maker's take on this project: