Matt Denton: How we built BB-8 for Star Wars

What does it take to make a character feel alive when that character is made of mechanics, code, cables, and performance?

In this episode, Ben Hanlin sits down with animatronics expert and robot inventor Matt Denton to unpack the craft behind some of modern cinema’s most memorable practical creations, most notably BB-8 from Star Wars: The Force Awakens, but also work connected to Harry Potter, Project Hail Mary, and the wider world of robotics and film effects.

This conversation exists because great screen characters are rarely “just designed.” They’re engineered, tested, puppeteered, compromised, rebuilt, and refined under pressure. What emerges here is not just a story about robots or puppets, but a deeper look at how technical problem-solving becomes emotional storytelling.

If you’ve ever wondered how a sketch on a Post-it note becomes an iconic film character, or how practical effects still survive in an increasingly digital world - this episode is a fascinating look behind the curtain.

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