Welcome back to planDisney, Tonya! It's great to see you again. Thanks for asking your question about the approximate size and weight of the droids guests can assemble at Droid Depot in
Star Wars: Galaxy's Edge. I'd be happy to answer your question, discuss shipping costs, and help you know what to expect if you're planning to carry your droid with you aboard a Star Tours flight back home.
There are two astromech droids to choose from at
Droid Depot, and they are slightly different sizes once built. BB-series units are roughly 7 inches deep and wide and about 12 inches tall if you include the antenna. R-series units are roughly 8 inches deep and wide and also about 12 inches tall. Both droid styles will fit comfortably in their own hexagonal box which measures 11 inches deep, 11 inches wide, and 18 inches tall. I'd estimate the weight of the droid and its box to be less than 5 pounds, so it's a manageable item to carry with you, though you may find the box to be slightly bulky.
If you'd prefer to ship your droid back to your home planet from Batuu, simply speak with the clerk in the Depot. They will be able to give you a proper estimate of the cost in credits to safely package and deliver your droid. Prices are subject to change, but I think you can safely budget around $20 for shipping. If you plan to bring your droid aboard your Star Tours transport back home, I recommend checking any applicable luggage policies listed by your airline. I assume they will count your freshly-built creation as part of your carry-on and personal item limits, so make sure to consolidate bags or let someone with fewer items carry it on board.
I hope this helps you plan for an out-of-this-world droid building experience, Tonya! If all that assembling has you working up an appetite, you can satisfy your hunger with a scrumptious Ronto Wrap at
Ronto Roasters or sink your teeth into the delightfully crispy Endorian Fried Chicken Tip Yip at
Docking Bay 7 Food and Cargo. I am wishing you a fantastic visit to Walt Disney World and Batuu!
May the Force be with you,
Scott