Marvel asked content creator Frank to build a working replica of H.E.R.B.I.E., the robotic assistant from The Fantastic Four: First Steps, for the film's blue carpet premiere. With only seven days of time and help from engineer Danny, Frank built a fully animatronic H.E.R.B.I.E. using custom 3D models and off-the-shelf components.
A two-wheeled balancing robot called Diablo was used as H.E.R.B.I.E.’s base to let it move around. Its body was 3D printed using PLA plastic, then sanded and painted. Nikko Industries gave them detailed 3D models and real-time revisions based on references from the actual set of the film at Pinewood Studios. The team broke down the design of the robot into four parts: arm movement, neck articulation, eye motion, and mounting structure. The arms made use of planetary gears to reduce servo strain. The neck system took inspiration from WALL-E robots and was designed in a way that allowed H.E.R.B.I.E. to pan and tilt naturally. Eyes as well as mouth parts were animated using DC motors and linear actuators, mounted behind a custom acrylic faceplate.
H.E.R.B.I.E.’s electronics were powered by an ESP32 board, which made it controllable wirelessly through Bluetooth using a PlayStation controller. Separate motor and servo drivers were used to handle the different power and signal needs. Due to shipping limitations, the final electronic testing occurred right before the event. H.E.R.B.I.E. was a huge success at the premiere, drawing praise from Marvel staff who mistook the replica for the production unit. The build was all done in time for Open Sauce Live and the premiere, standing to show what a passionate maker team can achieve even under pressure.
