Here's a new puppet I started

It will have mouth open and side to side jaw motion

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What is the best way to make a mechanism like this out of aluminium armature wire?

Greyguy said:

Here are the teeth start and sculpted in epoxy

they are really two differant ways of making heads

wire is atached a skull and then glued to the mask

Nick Hilligoss has some nice info on wire armatures

The shot on the right is of the old linkage that worked ok for the chin but on the other side was the same mechanism that worked the tongue that when the jaw went left it would make the toungue move out which I did not want ! So the new cable/linkage on the right image will work the way I want it to by when the jaw goes thru it's motion the chin and tongue will not be effected 

Wire is the cheapest, and by far the quickest and easiest way to make a head with some movement. It isn't the BEST, but sometimes it can be good enough. For example, a wire jaw will allow you some sideways movement, as well as opening and closing, just because it is wire. But because it can get squished into an almost infinite number of shapes, it can be very hard to get it back to the original neutral shape, burried inside the foam or silicone, with no distortion. Balljoint toggles do that better. And for small precision movements, geared mechanisms like this offer far more control. So what Greyguy is doing here is "best" - but it takes time, tools, and skills we don't always have.

 
 Here is a bracket that will hold four little clevis that will allow the brows to move up/down and also pivot.
Just want to see if this will add a little more expession to the brows by allowing the little bit of inward brow motion.The outer brow will move inward on alittle cam lever to the center of the forehead and the inner brow will be able to float around and do what ever it needs to do  :)

Gorgeous!

If that bronze disk is a 3 0r 4 inch drinks coaster, heck I coulda made that aloominum thingie!   But if it's a US 1 cent coin,  that's some amazing miniaturisation!

Once you get beyond a certain level of fine details in a photo of a mechanism, I can't really make out how it works and just think, wow this looks cool.   You've moved well into that zone with this head.   So it's nice to look at just one small component that's simple enough for my brain to take in.

One question - what is a clevi?  (four little clevis...)

I've heard the term 'clevis pin' before, but not sure what it meant so I did a little googling:

Judging by the ruler, these look a bit bigger than what Double G is making.. 

The clevi size is .125x.125x.220 and the slot is .032

Sorry about the unclear photo.The clevis pivots on a screw that will give the brows some inward motion.So when the outer brow moves down it will pivot inward on a little cam like lever to make it go inward as it moves down. I took the picture with the clevi in differant positions o show how they can pivot.

It is just fun to think of an idea of what I want for movement and then design and make it and have it work out.

Also I want to make some small hinge joints and this is getting me excited about doing that at that scale!

I just worry that once you've finished making this your jut going to cover it all up with  puppet and no-one will get to see all this amazing handiwork. Have you thought about doing a robot film?

Amazing handiwork, beautifully machined and I imagine its a dream to animate with

Close up to show the screw

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