Modern stop-motion animation for movies – gears, 3D printing

From the article:

Although mechanical heads are used for most of the key characters in the film, Pinocchio himself was animated with replacement faces. Because he has to look like he’s made of wood, he needed to have a hard surface, the animation supervisor Brian Leif Hansen said, explaining that 3,000 of the faces were printed. “His expressions are snappy; the mechanical faces look softer and more fluid compared to Pinocchio. He’s built differently and animated in a different way to set him apart.”

The character is the first metal 3-D-printed puppet, Hansen said. Because he’s skinny, “the only way they could make him strong enough was to print the puppet in metal. He’s a strong little guy, quite difficult to break. The animators loved animating him.”