At the heart of Shanghai Disneyland, characters that once graced the silver screen now inhabit our realm, allowing park-goers to feel as if they've plunged straight into their favorite movie. For Asha Xue, an artisan sculptor with Walt Disney Imagineering, this is particularly thrilling. A huge fan of Walt Disney Animation Studios' "Zootopia," she recalls dashing home to rewatch the film the moment she heard that a new land themed around the movie would be built in Shanghai, so she could study the intricacies of every character.

Behind these lifelike figures lies the magic of Audio-Animatronics technology: robots built with sophisticated mechanics and an attention to detail that brings them to life. Xue, alongside her mentor, Heather Greene, a principal illusion maker boasting over 25 years' experience in the craft, are the masterminds behind this Disney magic.

A photo displays the Audio-Animatronics figure of the iconic Chief Bogo in Shanghai Disneyland's Zootopia. [Photo courtesy of Shanghai Disney Resort]

When this new land opens on Dec. 20, guests will have the opportunity to encounter many Zootopia characters brought to life by this technology, from the most famous Judy Hopps and Nick Wilde, to many other guest-favorites such as Clawhauser the cheetah and Yax the yak. One that stands out is the figure of Chief Bogo, a brainchild of Greene's team. "It is amazing because it looks as if he's just stepped out of the movie when you walk into that room in the attraction's queue, like 'wow, he's there'," Greene noted with evident pride. Yet the journey to perfection isn't straightforward. Greene and Xue highlighted the intricate process, from the precise trimming of fur to the artful application of natural color hues, all while ensuring the figures retain their dynamic movements.

"Figure trimming is akin to a customer walking into a hair salon to get their hair cut. However, it's essential to understand the customer's needs and their personal image," Xue said. "We approach figures in the same manner. Initially, we search for reference images from the movie, then comprehend the figure's personality traits. Using these reference images as a guide, we trim its fur or even style it."

To guarantee durability isn't solely about rigorous UV and light tests on specialized paints and dyes; it's equally about the craftsmanship involved. 

A photo shows Asha Xue (right), an artisan sculptor with Walt Disney Imagineering, and Heather Greene (left), a principal illusion maker with Walt Disney Imagineering, smiling and looking at the Audio-Animatronics figure of Clawhauser they are working on. [Photo courtesy of Shanghai Disney Resort]

After an illustrious eight-year tenure with Disney, Asha Xue's name has become synonymous with craftsmanship. Initially an on-site artistic instructor, Xue later pivoted to sculpting iconic movie figures, making significant contributions to Zootopia. Her sculptures, capturing the essence of the film's characters, grace the facades, rooftops and interiors of the show's scenes. Recognizing her talent, Disney integrated her into their specialized figure finishing team.

Take the figure of Yax, for example. Designed with unkempt hair and buzzing flies, this figure was a testament to collaborative dedication. The detailing — reflective materials for the flies' wings and flexible wires to ensure movement — captures the very essence of the shot in the movie, which is a testament to the combined expertise of both Greene and Xue.

Beyond technical aspects, the duo's relationship is key. Under Greene's guidance, Xue has thrived, honing her artistry in fur trimming and painting. Their bond is rooted in mutual admiration, a shared passion and a drive to innovate. Greene's hands-on mentoring style and her strong curiosity have left an indelible mark on Xue.

A photo displays the Audio-Animatronics figure of Clawhauser, the rotund cheetah dispatcher, in Shanghai Disneyland's Zootopia-themed land. [Photo courtesy of Shanghai Disney Resort]

Greene emphasized that collaboration is vital in designing and producing Audio-Animatronics figures. "The discipline is wholly collaborative, and communication is 100% necessary in all that we do. Luckily the team at Walt Disney Imagineering is fully about collaboration, so from the very beginning — creative through engineering through surface development and animation — we are working together and communicating to bring that character to life," she said.

Xue echoed this sentiment, lauding the diverse strengths within the team. "Every member brings a unique perspective, ensuring the end product is nothing short of perfection," she added. "For instance, when we were working on the mouse tail for the 'mouse wheel' in Zootopia Fitness, one of the fun and active scenes in the land, we wanted it to be dynamic and so we were all trying to figure out how to do that. While I usually focus on the external appearance of a character, I do not have to fully understand the inner structure. But other team members, like those responsible for mechanics and electronics, would offer suggestions. For example, they might suggest adding a spring inside or suggest methods to secure the mouse tail to the shell, ensuring its dynamic movement. It's truly a collaborative effort among the teams working on these figures."

A photo shows Heather Greene (right), a principal illusion maker with Walt Disney Imagineering, and her protégé Asha Xue (left), an artisan sculptor with Walt Disney Imagineering, working on the Audio-Animatronics figure of Yax the yak. [Photo courtesy of Shanghai Disney Resort]

Judy Hopps stands out as Xue and the team's pièce de résistance, their design radiating the character's inherent brightness and positivity. "When we created this figure, we fully replicated her image from the movie. We also added a dimple to her smile, making her look and move in a way that evokes a joyful feeling."

With continuous advancements in technology, robotic figures are becoming increasingly lifelike. Combined with the skills of these talented makers, the future of Audio-Animatronics technology at Disney is poised to be not just bright, but also dazzling. The boundary between "reel and real" is blurring, and for Xue, that's the real magic: "pulling characters straight out of the movies and making them a reality."

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