I do not remember seeing any rule stating that robots cannot look human (or alien depending on the race in question). I think they can look like whatever they need to look like to get the job done. I personally envision them as they are portrayed in the movie The Adventures Of Pluto Nash. That whole movie seems to have many interesting things to incorporate into a human-based TE game.
Monolith, the Living Titan
"The HERO System is not designed to represent real life. The game is designed to represent heroic fiction as presented in comics, novels, television, and movies."
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