Daleks – Edward Felix

PROJECT CASE STUDY

Daleks.

Using fan projects to experiment with new systems and production methodologies in an unconstrained manner.

A dalek being photographed in my kitchen of an evening.

OVERVIEW

Built to look right. Engineered to perform.

Project: Dalek Builds & Restorations
Role: Design, Engineering, Fabrication, Electronics, Restoration
Skills: Mechanical Design, Fabrication, Embedded Systems, Wireless Control, Animatronics, Prop Restoration, CAD Design

Over a number of years, I have designed and built a range of Dalek props inspired by Doctor Who, spanning multiple eras of the show.

These projects range from small-scale models through to full-size, fully functional builds, using a mix of fabrication techniques including 3D modelling, fibreglass construction, metalwork, and embedded electronics. Each build serves as both a recreation and an opportunity to explore new approaches to control systems, fabrication methods, and performance design.

Alongside personal builds, I have also been commissioned to repair and restore Dalek props in private collections, as well as pieces used in exhibitions and licensed productions. Over time, this has led to a somewhat unofficial reputation as someone who consistently has more than one Dalek in the house.

The newly built modern dalek with a popping photoshoot in Melbourne.

Design, Engineering & Live Control Systems

The most recent build is a full-size Dalek based on the modern bronze designs introduced in 2005. Constructed from fibreglass and steel, the unit is fully radio controlled, with a long-range wireless system capable of transmitting both control data and live audio over hundreds of metres.

This allows the Dalek to be puppeteered in real time, with the operator’s voice streamed into the system, processed onboard, and reproduced with the distinctive cadence associated with the show. The result is a performance-driven prop that functions as both a mechanical system and a live character.

Due to the scale and power of the unit, safety and reliability were central to the engineering approach. The control system continuously monitors signal integrity at high frequency, with any significant interruption immediately halting all motion.

A deadman’s control ensures the operator must actively engage movement at all times, while multiple independent emergency stop systems within the Dalek provide redundant shutdown pathways.

Beyond the individual build, the control and processing systems developed for this project have formed a reusable foundation for future work, particularly in applications involving live puppeteering, animatronics, and interactive prop systems.

As a lifelong fan of Doctor Who, these projects continue to serve as an ongoing platform for experimentation, refinement, and exploration across both creative and engineering disciplines.

A bronze NSD dalek raised up for easier access during construction. — The Dalek raised up for easier access during construction.

Experimenting with full size 3D printed dalek sections. — Experimenting with full size 3D printed dalek sections, here a set of fibreglass “shoulders” are next to 3D printed ones that haven’t yet been cleaned up.

The internals of a 2005 NSD dalek eye CAD — To capture every desired control, the “eye” was engineered carefully. With a linked mechanical iris, recessed lensing system, as well as a false globe that hid and actively cooled LED, it was a tight squeeze!

A dalek plunger mould design. — To achieve the look of the modern dalek “plunger” while still being safe in public, a mould was designed and manufactured, which could cast a soft silicone piece in a pressure tank.

Testing dalek dome head pieces — Testing the dalek lights as well as the radio control operation of dome movement.

bronze 2005 nsd dalek patrolling streets at night — The completed dalek rolled out onto the streets at night!

Bronze 2005 NSD dalek with louise jameson in Melbourne Australia — The completed Dalek with Loiuse Jameson at an event in Australia.

Jason Haigh-Ellery managing director of Big Finish piloting the radio control dalek — The managing director of Big Finish, Jason Haigh-Ellery, taking control of the dalek, driving around and talking using the radio control systems.

movie dalek loading into a van — Edward loading a different dalek into a van for an event. The towels keep both the van and the Dalek safe.

Edward checking something on the dalek at an event — Whilst it’s best not to ruin the magic, at times it’s important to check under the hood of a dalek to ensure everything is secure.

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