FACEHEAD.CO
FACEHEAD.CO is a premier design STUDIO specialising in animatronics and special creature effects for film, television, and fine ART production.
STUDIO
With over 25 years of global production experience, Joshua Head established FACEHEAD.CO as a purpose-built 400 square meter studio in northern NSW, Australia.
The studio provides an in-house digital pipeline for animatronics, mechanical effects, sculpture, interactive electronics, embedded systems, PCB design, coding, custom control software, performance systems, and rapid prototyping.
FACEHEAD.CO combines large-format 3-axis CNC machining, DLP and FDM 3D printing, 3D modelling, CAD/CAM workflows, traditional clay sculpting, embedded systems, PCB design, and custom control software to deliver production-ready practical effects and advanced fabrication for film, television, exhibitions, and fine art.
PORTFOLIO
Cu Li Never Cries
2024
Animatronics Designer
Talk to Me
2022
Animatronics Designer
Blaze
2022
Animatronics Designer
2022
Animatronics Designer
Pieces of Her
2022
Props Designer
Thor: Love and Thunder
2022
Props Designer
2020
Suit Costume department
Penguin Bloom
2020
Animatronics Designer
Iron Sky: The Coming Race
2019
Prosthetics Sculptor
Pirates of the Caribbean: Salazar's Revenge
2017
Prosthetics Sculptor Mould Maker
Anklepants: Just One of the Guys
2016
Prosthetics Sculptor Mould Maker Director Writer Actor
Stung
2015
Animatronics Designer
Schoßgebete
2014
Prosthetics Sculptor
Rosa Roth
2013
Prosthetics Sculptor
Werewolf: The Beast Among Us
2012
Animatronics Designer Supervisor
Storage 24
2012
Prosthetics Designer
Prometheus
2012
Special effects
Where the Wild Things Are
2009
Special effects Technician Creature department
X-Men Origins: Wolverine
2009
Prosthetics Technician
Australia
2008
Prosthetics Technician
Rogue
2007
Mould Maker Foam Latex Technician
H2O: Just Add Water
2006
Prosthetics Technician
The Marine
2006
Prosthetics Technician
The Host
2006
Special effects Technician
See No Evil
2006
Prosthetics Technician
Aquamarine
2005
Prosthetics Technician
Hercules
2005
Prosthetics Technician
Star Wars: Episode III - Revenge of the Sith
2005
Prosthetics technician
Farscape: The Peacekeeper Wars
2004
Prosthetics technician
2022 Props Designer
2016 Prosthetics Sculptor Mould Maker Director Writer Actor
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2012 Animatronics Designer Supervisor
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ANIMATRONICS
ROBOTICS & FILM ANIMATRONICS
FACEHEAD.CO specialises in robotics and film animatronics, with a fully integrated in-house digital pipeline for creating and programming robotic creatures, animatronic characters, kinetic artworks, and responsive performance systems.
WHAT WE BUILD
Character animatronics
Mechanical creature effects
Kinetic sculpture systems
Interactive installations
Wearable and body-integrated mechanisms
Embedded systems and PCB-enabled control hardware
Custom performance rigs, coding, and control software
TECHNICAL CAPABILITY
The process spans digital sculpting, 3D scanning, CAD design, digital mould-making, embedded systems, PCB design, coding, fabrication, and finishing. By integrating design, engineering, electronics, and programming within the studio, FACEHEAD.CO can move efficiently from virtual design to physical production.
CONTROL SYSTEMS
Custom performance system coding and control software are developed around the needs of each project, from creature movement and animatronic performance to interactive installation, kinetic sculpture, and mechanically complex artworks.
SCULPTURE
HYPER-REALISTIC SCULPTURE
FACEHEAD.CO creates dynamic, hyper-realistic sculpture for camera, museum, exhibition, and fine art contexts, with a focus on lifelike human textures, forms, animals, creatures, and mechanically expressive surfaces.
PROCESS
The studio produces silicone skins, prosthetic-grade skins, joints, facial expressions, creature forms, mould systems, armatures, paint finishes, and final art finishing with a balance of digital precision and practical material knowledge.
DIGITAL PIPELINE
Using ZBrush digital sculpting, 3D scanning, digitising of practically sculpted works, high-resolution resin printing, and advanced mould-making workflows, FACEHEAD.CO develops hyper-realistic pieces for both screen production and physical exhibition.
TRADITIONAL CRAFT
Alongside the digital pipeline, FACEHEAD.CO remains deeply grounded in traditional sculpting, prosthetic makeup production, mould-making, archival materials, and fine art finishing. This allows the studio to deliver work that is technically precise, durable, and rooted in time-tested craftsmanship.
APPLICATIONS
Film and television creature and character work
Museum and exhibition sculpture
Fine art and collector commissions
Hybrid practical and digital production assets
CAD
CAD & DIGITAL PRODUCTION PIPELINE
At FACEHEAD.CO, CAD serves as the backbone of an advanced digital pipeline for practical effects, animatronics, fabrication, and VFX-heavy productions. The studio uses digital design to bridge physical builds and digital effects, creating accurate models that can move cleanly between screen, workshop, mould-making, machining, and final production.
CAD
The process includes Rhino 3D and Grasshopper for precise 3D modelling and parametric design, ZBrush for detailed digital sculpting, and hard-surface modelling tools for complex geometries, mechanisms, and production-ready components.
ELECTRONICS & CONTROL
FACEHEAD.CO also uses CAD and PCB design tools, embedded systems, coding environments, and custom control software to develop electronics, lighting control, and control systems for robotic creatures, animatronic performance systems, kinetic artworks, and interactive installations.
PRACTICAL TO DIGITAL
By integrating CAD/CAM, digital sculpting, 3D scanning, PCB design, software, lighting control, CNC machining, 3D printing, and traditional fabrication, FACEHEAD.CO connects practical craftsmanship with advanced digital workflows for accurate, repeatable, and production-ready outcomes.
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3D PRINTING
FDM & DLP 3D PRINTING
FACEHEAD.CO offers over a decade of specialised experience in FDM and DLP 3D printing for practical effects, prototyping, sculpture, engineering components, mould-making, and production fabrication.
The studio works across a broad spectrum of applications, from high-temperature and high-strength engineering materials to intricate sculptural and multi-material elements with flexible components.
FDM printing is used for robust, high-performance parts that need to withstand demanding conditions, while DLP printing enables exceptional detail and precision for sculptural, mould-making, and production components.
Both FDM and DLP technologies are available in-house in medium to large format. FACEHEAD.CO provides design support tailored to each project, whether the outcome is a durable engineering prototype, detailed artistic sculpture, flexible component, mould tool, or production-ready printed part.
CNC
LARGE-FORMAT CNC MACHINING
FACEHEAD.CO provides heavy-duty large-format CNC machining for practical effects, sculpture, mould-making, tooling, ornate timber carving, relief work, bespoke architectural panels, complex mechanical parts, fabrication, and production-ready assemblies.
The studio handles a wide range of materials from foam to steel, supporting everything from large sculptural forms and mould systems to decorative carved surfaces, architectural features, complex mechanical parts, armatures, and custom fabrication components.
FACEHEAD.CO's heavy-duty 3-axis CNC machine is equipped with a multi-tool changer, allowing complex RhinoCAM tool paths to be executed with efficiency, accuracy, and repeatability.By combining CNC machining with RhinoCAM, CAD/CAM workflows, digital sculpting, 3D scanning, mould-making, and practical fabrication experience, FACEHEAD.CO can deliver high-quality results across diverse materials, carved detail, relief surfaces, mechanical assemblies, and project requirements.
CONTACT
For project briefs, collaborations, or production support, contact FACEHEAD.CO
The studio works with production companies, agencies, museums, artists, exhibition teams, and international clients across animatronics, robotics, sculpture, embedded systems, PCB design, custom control software, rapid prototyping, 3D printing, CNC machining, and advanced fabrication.
Stay connected with FACEHEAD.CO
Explore our latest animatronics, robotics, special creature effects, fabrication projects and behind-the-scenes work on YouTube, Instagram, Facebook and Wevolver.
For project enquiries, collaborations or commissions, please contact FACEHEAD.CO via this page or email