An animatronics system and method for incorporation in talking toys, puppets, animated special effects and costumes. The system utilizes a removable storage device such as a flash memory chip to store pre-programmed audio and animation data and a microcontroller configured with both an audio player and an animation player. The microcontroller is adapted to access the audio and animation data and play the data in a manner such that the system produces synchronized sound and movement. The system also incorporates an auto-tuning system which automatically calibrates the system to compensate for variations in the arrangement of mechanical components in individual units.