Re: AIs, automatons, etc. as PCs
There was a character in one of the later 4th Ed. "Enemies" books, the Yeoman, which was essentially a free-willed android. There's a character in my campaign that's also essentially a free-willed android. Characters like Red Tornado and the Vision, from the comics are also that type of character. However, such characters should be built as normal characters, with Powers to represent their mechanical forms.
An AI in a box, like say, ORAC, really should only be an NPC. Imagine the player's reaction when he realises no one picked up his character to take him along.