Note. I am not the original creator of Portal 2. All rights go to their respective owners. Copyright Disclaimer under Section 107 of the copyright act 1976, allowance is made for fair use for purposes such as criticism, comment, news reporting, scholarship, and research. Fair use is a use permitted by copyright statute that might otherwise be infringing.
Process & Inspiration
I started by taking a look at how the character of "P-body" from Portal 2 was constructed. He is a long and slender robot, with several mechanical apparatures in between his joints.

I wanted to simplify his design for the sake of making the animation more minimalistic.
First i drew up his joints and connected them, then started working on a more oval
looking bodyform. I also decided to make the eye the centerpiece of his body.

After that I added details like the different black lines, eye ring, and orange button.
Below you can see a comparision between his original design, and my simplifed version.
Character Rig
After experimenting with different combinations of joint-movements, I settled on one that makes it possible to convey more expressions. As his eye never changes, the joints have to be able to express more emotion.

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