Our brief was to design and build an Animatronic Costume based on an existing graphic character used on packaging and posters.

They wanted Cola Cao to have plenty of character and, therefore, needed an expressive face.  The actor also had to be able to move energetically within the costume.

We designed a suit to be worn by a small performer who has experience as a dancer and gymnast. This involved lifecasting him, sculpting the character, moulding all the parts and casting them in foam latex.

The head had radio controlled animatronic functions facilitating eye movement and the mouth opening, closing and smiling.  We also made brows/antenna which could move to enhance expression. The whole thing and our crew travelled to Barcelona for the shoot.