Though the robot's head is meant to literally be a cardboard box, I felt that it should be made rather than actually using a box. This allowed a little more control in it's design and strength. Initially I made a prototype in order to work out the structure and sizes (shown above).
Then refined these measurements to create a net. The cardboard available wasn't big enough for a full net, so the front, side and top are connected and the back section is a separate panel. This allowed the front of the box-head to appear a little smoother, as if it were a whole thing. The net was intentionally slightly sloped at the front to achieve a slight asymmetrical look.
To distinguish it a little from 'just a box' and give it a little personality and age, I added eye bags. This coincided with the designs I had done previously. This was done with cardboard and then paper-mached over with brown paper, giving a slightly sunken feel to the eye holes. The box had tabs and flaps in order to cover the neck and attach to other pieces.
To secure the box to the head I fixed a headband inside and added a few extra panels to strengthen it.
Overall U1's costume is very similar to it's design. By spray painting the high-vis jacket to look a little dirty, the overall grimy effect was achieved without having to spoil clothes that were borrowed.
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