The animatronics industry is about to be flipped on its mechanical head as Chuck Fawcett and Steve Andersen, two of the industry’s most powerful forces, are back with the launch of their new company, FGR8, the next level of animatronics.
With over 30 years of innovation, invention, and magic behind it, FGR8 is set to create, construct, and deliver authentically detailed animatronic characters, bringing beloved characters and stories to life for the world’s biggest brands.
“We don’t just create the most realistic and believable animatronics on earth,” says Fawcett, FGR8’s president and chief creative officer, “we create the impossible. FGR8 is not just about carrying on the work we started; it’s about reimagining the potential of animatronics, blending the timeless magic of puppetry with tomorrow’s technology. It’s the Art of Animatronics.”
Fawcett has been making characters look and act real since he was 12 years old. He crafted much-loved Sesame Street characters as a teenager in the early 1980s, and since then, he has brought to life most of the character animatronics for major studios and theme parks worldwide, bringing to life big birds, talking mice, wizarding worlds, Jurassic dinosaurs, and beyond.
While still a senior at university during the 1980s, he established Animax Designs, leveraging his talents to transform it into an industry leader, vividly bringing to life the memorable characters cherished by children and adults globally.
A new chapter
Fawcett and his partner Andersen, the former EVP and head of operations at Animax, are now ready for a new venture, pushing the boundaries of organically driven animation solutions and soft robotics. They are investigating how emerging technologies like AI can improve character interactivity and elevate animatronics design, creation, and control. Fawcett adds: “It’s why we came back.”
Andersen, FGR8’s chief executive officer, is by his side, taking customers’ dreams and making them real. “We specialize in the seamless integration of internal robotic systems with external soft figure finish in animatronic characters,” says Andersen. He highlights the frequently overlooked connective tissue in physical character design, stressing the essential link between engineered mechanical parts and flexible materials.
FGR8 utilises cutting-edge design principles and weight optimisation methods to improve movement and realism, guaranteeing that the integration process results in characters that demonstrate fluidity and authenticity in their actions and interactions. Andersen says: “We go ridiculously far to make it real.”
Speaking about his excitement for the return of these two industry pioneers who are bringing true art to animatronics, Richard Taylor, co-CEO and chief creative officer at Weta Workshop, says:
“It’s hard to imagine the groundbreaking innovations that FGR8 will bring to life in the coming years. With Chuck at the helm and a formidable team around him, the next chapter in their animatronics journey will be nothing short of extraordinary.”
Technology, experience and a touch of magic
FGR8 brings its unique approach in several areas: technology, experience, and a touch of magic.
Its solutions will set industry standards by integrating advanced, puppetry-inspired animatronics with proprietary plug-and-play software. This combination enables the creation of fully authentic, lifelike characters enhanced by AI-driven interactivity, autonomy, and mobility.
The duo revolutionised control systems for the animatronics industry, and they’re still doing it. “Our innovative character animation and control software is a modular, scalable system that offers the ultimate flexibility and control others can only dream of,” says Andersen. Their zero-effort control systems integrate lifelike figure control with audio, video, lighting, and projection. No shake, no jitter; fully controlled motion, both slow and fast, with a full dynamic range, all at your fingertips.
And this isn’t Fawcett and Andersen’s first rodeo; their impressive resume supports their reputation. It’s no exaggeration to claim that billions globally have interacted with their creations, which are everywhere. They’ve designed and built the world’s largest, most lifelike, and intricate electrically operated animatronic figures and characters. Their contributions have animated cherished characters for major brands and theme parks, including Disney, Universal Studios, DreamWorks, Nickelodeon, Warner Bros., Sesame Workshop, and others.
But it’s not just about the technology for FGR8. It’s about the magic, says Fawcett: “We make characters that look, move, and feel real, interacting, talking, playing. But ultimately, we make magic. The magic of a little girl looking up and seeing her hero or secret friend standing right there. Alive. Talking to her. Holding her hand. We create characters that can’t exist in our physical reality; it’s impossible. And yet there they are, right in front of you.”
Bringing the impossible to life
After the pair departed from Animax a few years back, many in the industry have been eagerly anticipating their return.
“The achievements of Chuck and the FGR8 team in the field of puppetry and animatronics are nothing short of revolutionary,” says Jeff Conover, creative director at Walt Disney Imagineering. “They have mastered the art of character creation, blending design, movement, and emotional depth in their work.”
Fawcett and Andersen don’t aim to build the largest animatronics company; they prefer to call FGR8 a “boutique” offering, working with select top-tier customers seeking the next level of character animatronics. The new venture is strategically placed to shake up the industry, with multiple notable partnerships already underway.
“We’re not going to make the most,” says Andersen, “but you can bet your life we’re going to make the best!”
Fawcett and Andersen have been pivotal in driving significant innovation in the animatronics industry over their 30+ year careers.
“And we’re just getting started,” says Fawcett. “We’re taking everything we’ve learned and created, and applying new technologies, new ways of thinking, and new ways to generate truly authentic experiences and characters, pushing the envelope every time. At FGR8, we’re truly bringing the impossible to life.”
That, he says, is the true Art of Animatronics.
