World's first?Full 3D printable ornithopter

Assembly instruction

February 2014Yusuke Takahashi

(Fablab Kitakagaya/The Flapping Wing Factory)

The ornithoper "Flying Pants" wasoriginally developed by author as a FABLAB

workshop item in 2013.

The original version was made of hybrid materials such as SLS(*) printed parts and carbon rods.

SLS(Selective Laser Sintative): One of the high-end 3D printing technologies

In 2014, personal 3D printers are becoming more and more affordable, so I revised the

parts design suitable to these printers.

The new design is suitable for any personal FFF(fused filament fabrication) type 3D printers

like as Reprap, Replicator, and Cube, etc.

CAD data file of the parts can be freely downloaded at Thingiverse or 123dapp.com.

Thingiverse: http://www.thingiverse.com/thing:239789

123dapp.com:http://www.123dapp.com/smb-123D_Design/Flying-Pants/2107482

You can also order the 3D printed parts to Shapeways or DMM.com.

Shapeways:http://www.shapeways.com/model/1693498

DMM.com:http://make.dmm.com/item/30182/

Specification of "Flying Pants":

Wing span: 300 mmLength: 135 mmWeight: around 2.5 gramsPower source: medium size rubber band * 2Suitable materials: polyamid(SLS*) or ABS(FFF)

* Select "White Strong & Flexible" (Shapeways)"ナイロン (ポリアミド )"(DMM.com)

You also need a small paper clip for the crank anda thin plastic bag for the wing membrane.

Step 1:Parts check and preparation

Parts are often printed with a raft and supports.They should be removed and cleaned up carefully.

Step 2:Parts clean-up

A raft may be peeled off by hands.Supports should be removed using cutter knives.Parts surface can be finished by engineers files.

Finish carefully!

Step 3:Assembly of the right arm and the frame

The right arm is fixed to the frame.They are designed as snap-fit, but you can fix

them by a drop of instant glue.

Step 4:Assembly of the left arm and the frame

The left arm is a moving parts.The arm should be able to flap freely.

If it won't flap smoothly, enlarge the holes of the arm by drills or reamers.

Step 5:Making of the crankshaft

The crankshaft can be made from a small paper clip. Bend it carefully using a needle nose plier

and cut an excess off.

Step 6:Making of the crankshaft

The crankshaft can be made from a small paper clip. Bend it carefully using a needle nose plier

and cut an excess off.

3mm

Step 7:Making of the crankshaft -Finish

The crankshaft can be made from a small paper clip. Bend it carefully using a needle nose plier

and cut an excess off.

8mm

8mm8mm

Step 8:Assembly of the crankshaft and the frame

The crankshaft is inserted into the holes of the frame.

Step 9:Assembly of the crank and the rocking arm

Slot the crank pin into the slit of the rocking arm.

Step 10:Hook rubber bands

Hook a pair of rubber bands to the crank end and the frame.

Step 11:Test run

Wind the crank up about thirty times.As the crank rewinds, the left arm will flap

bouncingly.

Step 12:Cut out the wing membrane

Cut the wing membrane out from a thin plastic bag* using cutter knives.

* film thickness < 0.01 mm would be better

300mm

135mm

Step 13:Apply the wing membrane to the frame

Apply thin strips of double-sided tape to the frame. And then apply the wing membrane carefully to

the frame along the tapes.

Step 14:Assembly finished!

Assembly finished.Bend the tail up slightly for a stable flight.

Let's take it out for test flights!

Step 15:Test flight

Test flights can be made either in the room or outdoors(in the calm, windless condition). Apply power by winding the crank up about thirty to fifty times. Hold the plane by your fingers horizontally, and push it off slightly upward,. If the plane dive straight to the ground, bend the tail up more or simply launch the plane upward. If it turns sharp to right of left, bend the opposite side of the wing chip slightly backward.

Some Hints of hacking the pants 1:Painting / marking

Painting or marking on the wing is fun!Colorful marker pens would be suited to the job.

Create your original pants.

Some Hints of hacking the pants 2:Weight reduction

You can upgrade the wing arms by carbon rods*. The weight is dramatically reduced to under 2.0

grams and you can enjoy longer flight time.* 0.7mm dia 140mm long size * 2

Cut Cut

Fix by instant glue

Carbon rod Carbon rod

About author:

Yusuke Takahashi (Flappingwing)

Location: Osaka, JapanA founder of The Flapping Wing Factory

Personally engaged in the development of small ornithopters for 10 years.

Member / operating staff of Fablab KitakagayaBlog: http://blog.goo.ne.jp/flappingwing/

http://www.youtube.com/user/flappingwinghttp://www.slideshare.net/Flappingwing/