Why Animatronics at Epic Universe Hit Different: Universal Talks on Tech Challenges and Taking Risks

I can't take my eyes off Dr. Victoria Frankenstein. I've seen plenty of theme park animatronics before but there's something otherworldly about how this robot was designed: her digitally animated face is projected on a physically animating head and it looks like a video game character has come to life. But just as I try to figure out what makes her tick, I'm distracted by the reveal of another jaw-dropping animatronic: her 800-pound, 9-foot-tall monster walking toward the audience.

Enlarge Image

It's only fitting that some of the most advanced animatronics created reside in Dark Universe, a spooky world where mad scientists push the limits of technology. This is one of five immersive lands inside Universal's Epic Universe, a new theme park in Orlando, Florida -- and the first major park to open in the US in 20 years. The park has been officially open to guests for a week but I got an early look at the tech during a grand opening event. I spoke with some of the team leaders who brought it all to life, which you can watch in the video embedded above.

For several years, I've been reporting on how technology is enhancing theme park experiences but I've never quite seen something at the scale that Universal has pulled off. Not only did the team patent new technology for characters like Dr. Frankenstein but it was impressive to see the sheer number of robotics scattered all over these themed worlds. 

At Isle of Berk, a land themed to the Viking world from the How to Train Your Dragon movies, there are 30 animated figures just lounging about -- some sleeping dragons, some blasting icy air, others just swinging near stores -- all exposed to Florida's harsh summer temperatures. 

Our visit was a sweltering one, with temperatures reaching 94 degrees -- and it will be be an increasing challenge with animatronics exposed to the elements, as scientists expect record-breaking heat in the next five years. 

"We had to do a lot of integration of elements into something as simple as our shade structures," said Ryan Paul, manager of ride and show engineering at Universal. He explained that it involves more than just an overhead covering, but a blend of show lighting, electrical work, plumbing and fans. "To keep everyone cool in the Isle of Berk, those alone were a challenge."

The dragons of Berk take on multiple robotic forms. Some are untethered, as cute baby dragons perform stunts and walk around guests. These young dragons move in a way that's reminiscent of other quadruped dog-style bots. 

The star of the land is a life-size, interactive and emotive Toothless that you can touch (and even feel him breathing). Expect a long wait for this fella: Even at a limited-access media event I was waiting 45 minutes to get up close with my first touchable animatronic, where a character actor stands beside to ease you into the moment. 

But multiple dragon caretakers gave us instructions not to touch the eyes or teeth, and keep our hands away from the dragon's jaw. It's not just about training dragons -- at a theme park, you have to train the humans.

Another animatronic version of Toothless flies over your head in a stage show. But Berk is full of dragons  and there are plans to include drones (er, flying dragons) to soar above the land throughout the day. Some guests have spotted one being tested in the park already.

"They are right on the precipice of adding those to the skyline here. And I think that'll really complete the picture," Paul said.

It's hard to spot every animatronic -- especially in the newest land themed to Harry Potter and set in 1920's Paris, where magical creatures hide in carts and water fountains. But inside the star attraction, Harry Potter and the Battle at the Ministry, there's a big coordination between robotics, screens and projections, all needing to be timed just right to pull off numerous eye-tricking effects.

But when you have more moving parts, it means more can go wrong. With robots woven into almost every aspect of entertainment here, Universal certainly faces more risk in keeping the experience smooth for guests with high expectations. 

"With anything new, comes risk," said Anisha Vyas-Burgos, an assistant director of projects who worked with teams at the new Wizarding World. "But I think that my favorite thing about Universal Creative is that we're bold, we take risks and we try to do something new."

In my preview visit I experienced all rides working fully but there was one "oops" moment. For my third time riding Monsters Unchained, I caught one animatronic not moving. And since opening day, guests post on social media about rides going down. Perhaps it's unrealistic to expect perfection in the early days of an ambitious new theme park. I hope they can keep the effects running as intended. As someone who follows emerging tech, it's delightful to see it used to bring fantastical worlds to life. Because tech, done right, really does feel like magic.