Successful realization of a flapping wing micro-air vehicle (MAV) requires development of a light weight drive mechanism that can convert the continuous rotary motion of the motor into oscillatory flapping motion of the wings. The drive mechanism should have low weight to maximize the payload and battery capacity. It should also have high power transmission efficiency to maximize the operational range and to minimize weight of the motor. In order to make flapping wing MAVs attractive in search, rescue, and recovery efforts, they should be disposable from the cost point of view. Injection molded compliant drive mechanisms are an attractive design option because of manufacturing scalability and reduction in the number of parts. However, realizing compliant drive mechanism using injection molding requires use of multipiece multigate molds. Molding process constraints need to be considered during the design stage to successfully realize the drive mechanism. This paper describes an approach for determining the drive mechanism shape and size that meets both the design and molding requirements. The novel aspects of this work include (1) minimizing the number of mold pieces and (2) the use of sacrificial shape elements to reduce the impact of the weld-lines on the structural performance. The design generated by the approach described in this paper was utilized to realize an operational flapping wing MAV.

Multi-material molding (MMM) enables the creation of multi-material mechanisms that combine compliant hinges, serving as revolute joints, and rigid links in a single part. There are three important challenges in creating these structures: (1) bonding between the materials used, (2) the ability of the hinge to transfer the required loads in the mechanism while allowing for the prescribed degree(s) of freedom, and (3) incorporating the process-specific requirements in the design stage. This paper presents the approach for design and fabrication of miniature compliant hinges in multi-material compliant mechanisms. The methodology described in this paper allows for concurrent design of the part and the manufacturing process. For the first challenge, mechanical interlocking strategies are presented. For the second challenge, development of a simulation-based optimization model of the hinge is presented, involving functional and manufacturing constrains. For the third challenge, the development of hinge positioning features and gate positioning constraints is presented. The developed MMM process is described, along with the main constraints and performance measures. This includes the process sequence, the mold cavity design, gate selection and runner system development. A case study is presented to demonstrate the feasibility of creating multi-material mechanisms with miniature hinges serving as joints through MMM process. The approach described in this paper was utilized to design a drive mechanism for a flapping wing micro air vehicle. Methods described in this paper are applicable to any lightweight, load-bearing compliant mechanism manufactured using multimaterial injection molding.

Towards design and fabrication of a miniature MRI-compatible robot for applications in neurosurgery.

Successful realization of a flapping wing micro air vehicle (MAV) requires development of a light weight drive mechanism converting the rotary motion of the motor into flapping motion of the wings. Low weight of the drive mechanism is required to maximize the payload and battery capacity. In order to make flapping wing MAVs attractive in search, rescue, and recovery missions, they should be disposable from the cost point of view. Injection molded compliant drive mechanisms are an attractive design option to satisfy the weight, efficiency and cost requirements. In the past, we have successfully used multi-piece molding to create mechanisms utilizing distributed compliance for smaller MAVs. However, as the size of the MAV increases, mechanisms with distributed compliance exhibit excessive deformation. Therefore localizing rather than distributing the compliance in the mechanism becomes a more attractive option. Local compliance can be realized through multimaterial designs. A multi-material injection molded mechanism additionally offers reduction in the number of parts. This paper describes an approach for determining the drive mechanism shape and size that meets both the functional design and multi-material molding requirements. The design generated by the approach described in this paper was utilized to realize a flapping wing MAV with significant enhancements in the payload capabilities.

Thermally conductive filled polymers enable the creation of multifunctional structures that offer both anchoring points for the embedded actuators, as well as heat-dissipation functions, in order to facilitate the miniaturization of devices. However, there are two important challenges in creating these structures: (1) sufficient thermal management to prevent failure of the actuator and (2) the ability of the actuator to survive the manufacturing process. This paper describes a systematic approach for design of multifunctional structures with embedded heat-generating components using an in-mold assembly process to address these challenges. For the first challenge, the development of appropriate thermal models is presented along with incorporation of in-mold assembly process constraints in the optimization process. For the second challenge, a simulation of the molding process is presented and demonstrated to enable the determination of processing conditions ensuring survival of the in-mold assembly process for the embedded actuator. Thus, the design methodology described in this paper was utilized to concurrently optimize the choice of material, size of the structure, and processing conditions in order to demonstrate the feasibility of creating multifunctional structures from thermally conductive polymers by embedding actuators through an in-mold assembly process.