Hi Cyndee! Thanks for bringing your question to planDisney.
You're going to love the experience of
building your own droid at Black Spire Outpost's industrial depot in
Star Wars: Galaxy's Edge at Disneyland Park,
subject to availability and pricing changes. My boys selected BB-Series droid builds. If I was choosing, I'd go with a C-Series, because I'm a C-3PO fan, but you can't go wrong with any of the options. A couple of years later and they're still in great working order, so we're very happy with our family's droids.
We brought them with us on the airplane to Missouri without any issues. They came home as carry-ons. The BB-Series went through security without any problems and fit in the overhead bins above us. I think TSA is fairly accustomed to seeing droid friends travel this way.
There are lots of droids scattered throughout Star Wars: Galaxy's Edge, and since my Padawans are big fans, we take lots of pictures with those hard-working astromechs. Additionally, there's usually a
Disney PhotoPass Photographer nearby the Millennium Falcon, and our photos turned out so great, we used one on our holiday card. If you're considering adding
Genie+, the unlimited Disney PhotoPass downloads are a real plus.
Good journey!
Elizabeth