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Disney Research in Zurich, Switzerland, has developed a new process called "Physical Face Cloning" that allows it to create realistic animatronic characters. The technology scans the head of a human before putting the coordinates and expressions into a 3D program.
Measurements such as skin and thickness are then used to produce a 3D printed mold of the face before a silicon layer of syntheic skin is attached. The result is a realistic-looking robotic head with accurate expressions and features such as wrinkles.
Disney will use the technology and process to produce life-like animatronic figures in its theme parks to add to the realism of the interactive characters. Watch the video below to see the entire process.