Design of a Flapping Wing Micro Air Vehicle Actuation System

Nicholas S. Baker, Mark Hayes, Daniel Smith, Ryan Damman

Ohio Northern University, Ada, OH 45810

Abstract
This paper describes the fabrication, development, and testing results for a proof-of-concept bioinspired flapping wing Micro Air Vehicle (MAV) actuation system designed by mechanical engineering
undergraduates at Ohio Northern University. The design project is sponsored by the Air Force Research
Laboratory (AFRL) as part of the Senior Capstone Design Challenge. After considering several design
alternatives for the wing actuator; including mechanical linkages and resonant structures, the team chose
to manufacture and implement dielectric electro active polymers (EAPS) as the actuating system. These
EAPs perform as artificial muscles that mimic living creatures better than mechanical systems. Dielectric
elastomers also have large strains, high output energy densities, quick response levels, and low noise
levels when compared with other actuators. A spray deposition method has been studied and is currently
being pursued to fabricate the Silicone based elastomers. This paper also discusses proposed EAP
configurations as well as the electrical power supply and methods employed for controlling the actuation
system.
1. Introduction
The United States Air Force has been pursuing design projects for surveillance vehicles that have
the ability to disguise themselves in plain sight. One of these avenues has been the research and
development of micro aerial vehicles, or MAVs. These vehicles often mimic the flight characteristics of
hummingbirds and dragonflies because of their size and unique hovering capabilities (Aerovironment Inc.
Nano Hummingbird) MAVs will be used as miniature surveillance instruments and will aid the soldiers
and civilians of the future.
The Air Force Research Lab (AFRL) has set requirements for the Micro Air Vehicle (MAV)
flapping wing actuator student challenge project. The purpose of the Ohio Northern mechanical
engineering senior capstone group is to complete these requirements set forth by the AFRL. The groups
overall objective is to design an actuation system to flap the wings of an MAV and to build a proof-ofconcept prototype to present to the AFRL. This specific MAV wing actuator will be designed to imitate
wing motion found naturally in living creatures.
1.1 Problem Definition
The AFRL has introduced a student challenge asking groups to design the actuation system for a
flapping wing actuator that flaps wings in a bio-inspired manner, meaning it flaps its wings like a bird or
insect. Designs are to take into consideration several methods for actuation, including rotary power,
linear actuation, and/or smart materials. Several characteristics of MAVs were provided in the problem
statement to provide an idea to the group of the design scale used by the AFRL and their design criteria
for a completed MAV. The deliverables to the AFRL include a prototype that demonstrates the flapping
motion, a 3D CAD model of the final design, and descriptions of how the proposed design could be
employed for use in an actual MAV.
In order to achieve a solution to this problem, the group has taken an approach which will lead to
success. Starting with research on past and current projects in the field of MAVs, knowledge has been
gained on current actuation methods. Based on the results of research, several possible actuators were
Proceedings of the 2012 ASEE North-Central Section Conference
Copyright 2012, American Society for Engineering Education

determined. A comparison was made using constraints which were set by the group members. These
constraints were influenced by the specifications and criteria for MAVs developed by the Air Force. A
visit to the AFRL headquarters at WPAFB enabled the group to learn the options and designs currently
being considered for MAVs. This helped the group make design decisions for the method of actuation
pursued.
1.2 Requirements
During a visit to Wright Patterson Air Force Base in Dayton, Ohio, the group was able to see the
current MAV projects and research being done by the AFRL. During the visit the group was able to get a
solid grasp on the scope of this design project. The AFRL has designated several design constraints that
their final, full scale MAV will have including; a mass of less than 15 grams, a flapping frequency of 25
Hz, and a wing span no greater than 15 cm. The student groups prototype will not meet such
requirements. The actual design and construction of the wings is beyond the scope of this project; it is
only to design the actuation system. Realistically, the AFRLs requirements for an MAV must be met by
a larger research and development team with more resources and man power than what is available for
this senior capstone project. The AFRL is currently working on this project and has been for several
years. The student challenges objective is to possibly present a new idea that may be implemented
through further research by the Air Force. So, the senior design group has set realistic criteria and
constraints for their design and prototype. The following are these criteria and constraints:
Criteria

Weight: One aspect of the individual part choices will be based on weight; lighter is better.
Flapping frequency: The frequency the actuator is able to flap the wings; a higher frequency
generates more thrust, which is ideal
Energy efficiency of Actuator
Size: Overall size of the actuation system; smaller is better; however, the prototype will be on a
larger scale due to manufacturing limitations.
Controllability: How will the actuator be controlled; simple controls are better; this is objective to
the group based on the complexity of the control system used to control the speed/direction the
actuation flaps the wings
Manufacturability: The group must design an actuation system for which they can manufacture a
proof-of-concept prototype using the available facilities and equipment.
Future innovative potential
Covertness: How well the actuation system can blend into the surroundings. This includes noise
level, and level of bio mimicry

Constraints
Considering the scope of this project, the constraints set for the design of the MAV flapping wing
actuator are more general in nature. The difficulty of achieving the AFRLs desired requirements for
MAVs prohibits the group from setting quantitative constraints. By successfully designing, building, and
presenting an actuator that can effectively actuate wings into a flapping motion and introduces a new
concept to the AFRL, the project will be considered a success.

Direct Drive Actuation: The system must directly drive the wings to produce an oscillating and
repeatable flapping motion
The prototype must be proven to be able to be downsized to the appropriate scale required for the
AFRLs MAV requirements
It must be shown that an onboard power supply can be implemented into the actuation system
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2. Alternative Designs
2.1 Mechanical Linkage:
One viable alternative that would produce linear motion to actuate the wing mechanism would be
using a rotary motor with gears along with mechanical linkages. This option would implement a single
rotary electric motor to turn one gear on its output shaft which then turns a set of two gears; one gear for
each wing actuation. Each gear would have linkages attached to it and to a pivot point. The output shaft
connected to the wing root would be designed to achieve between 120 and 140 degrees of rotation.
Another option to implement this idea would be to use a single gear on the output shaft of the
motor to move a linkage, which would control both wings simultaneously. This would reduce the
complexity of the actuator. Although these are two different options for the actuator, they are being
considered a single option here. Both options include the use of a mechanical gear and linkage
mechanism powered by a rotary motor 1.
2.2 Artificial Muscles
Artificial muscles are another viable option for the wing flapping actuator. The artificial muscle
considered is a dielectric electro active polymer (EAP). This smart material has the potential to expand
when a voltage is applied across the cross section and then relaxes to its original position when the
electric field is removed. Therefore with the correct electrical power, signal frequency, and position of the
muscles these artificial muscles could directly drive the wings at the correct frequency to achieve the
requirements for the MAV. The benefits of this option are substantial. With this option, the exact motion
of the wings can be modeled with a relatively simple and efficient design. The placement of these
artificial muscles will be based on the real muscle structure of the creature the group decides to model.
This concept would help improve flight kinematics and realism of appearance2.
2.3 Resonant Structure
A third alternative would be a resonant structure. Utilizing the vibration characteristics of a
structure at its resonating frequency is a highly energy efficient solution for actuating a set of wings.
Resonant structures have proven to be optimal over rotary mechanisms in very small MAVs. This design
alternative involves one or more elastic rings that are vibrated by a centrally located linear actuator. The
elastic rings transfer motion to an amplification mechanism or set of elastic hinges which rotate the base
of the wing spare to create the flapping motion. This indirect flapping motion closely mimics the flight of
most insects, excluding dragonflies. A centrally located linear actuation system is ideal for this design.
Three viable options include dielectric electro active polymer (EAP) actuators, electromagnetic voice
coils (solenoid), or a piezoelectric actuator. Feathering or wing rotation will be achieved through passive
means. The alternative provides an extremely efficient system but its limitations lie on the amount of
power and thrust that can be generated by the wings 3,4.
2.4 Evaluation of Designs
The main decision making tool used by the group was two modified Pughs decision techniques.
The modified Pughs method compared a rotary motor actuator, a dielectric electro active polymer (EAP)
actuator, and a linear motor actuator, and this was completed using the design parameters mentioned in
the previous sections. Weights were also added to the parameters. Energy per unit mass, noise level, and
level of bio mimicry were the highest weighted parameters followed in order by cost, efficiency, and then
Proceedings of the 2012 ASEE North-Central Section Conference
Copyright 2012, American Society for Engineering Education

innovative potential. After using two datums and completing two modified Pughs techniques, the EAPs
turned out to be the best option for the group to pursue. A more detailed representation of the groups
decision process can be found in the decision methods section of the groups design notebook.
Table 1: a Modified Pughs Method for Actuation Selection, EAP as datum, b rotary motor as datum
a

2.5 Proposed Solution

The final design for the actuation system utilizes a direct drive artificial muscle system. After
continued research on fabrication techniques for dielectric EAPs, it was felt that developing a fully
working and controllable actuation system in the given time constraints would not be possible if EAPs
were to be the actuation source. The group felt that providing a technology and knowledge base that
could be further perfected in the future was more valuable to the AFRL rather than presenting them with a
conventional design. Therefore the group contacted the AFRL for their opinion about pursuing dielectric
elastomers as the actuation system. The team was instructed to continue pursuing the fabrication of
dielectric EAPs. As a result the objective of the capstone project shifted more to a research based project.
Proving that EAPs can function in an MAV has become the primary goal.
3. Fabrication and Testing
3.1 Dielectric Elastomers
Dielectric elastomers are ideal for a flapping wing MAV and their material properties allow for
better performance than almost all other actuator technologies 2,3,5. The two polymers considered for the
actuation system consist of an acrylic based polymer, 3M VHB 4910, and a silicone adhesive, BJB TC5005. Both materials have low elastic stiffness and high dielectric constants, which enable them to
exhibit deformation under certain conditions. The polymer essentially acts as a capacitor and when an
electric field is applied across the thin films, which need to be sandwiched between two compliant
electrodes, the polymer is deformed. This occurs because the opposites charges attract and squeeze the
material in the thickness direction and the like charges repel which expand the polymers planar area in
the transverse direction. The effective pressure, p, as a function of voltage is given in equation (1)2:
(1)

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Copyright 2012, American Society for Engineering Education

where
is the relative permittivity of the polymer or dielectric constant,
is the permittivity of free
space, T is the applied electric field, V is the voltage, and h is the film thickness of the polymer. The
output force of the actuator can be related to the effective pressure by equation (2)2:
(2)
where is the thickness strain and E is the modulus of elasticity for the polymer. As a result the thinner
the polymer film, the less voltage is required to create the same strain output. In order to maximize strain
output the polymer films are layered between an electrode material, usually of carbon, and then stacked
into desired configurations. By loading the polymer in various configurations and thus restricting the
expansion in certain directions, manipulation of a combined output force can be achieved.
It has been shown that acrylic based polymers have exhibited max strain rates of over 300% with
maximum volume specific energy densities of 3.4 J/cm3, and a modulus of elasticity between 2 and 5
MPa. In order to achieve high strain rates, VHB tape must be prestrained prior to activation. This results
in poor predictions for performance because often the prestraining leads to varying in the modulus of
elasticity2. Carbon grease has been shown to be the most suitable compliant electrode material 6.
The Silicone based polymer currently being tested is BJB TC-5005, which has demonstrated
strain rates well over 100%, with maximum volume specific energy densities between 0.1 and 0.7 J/cm3.
For comparison muscle tissue has an energy density of approximately 0.07 J/cm 3. The polymer is a two
part adhesive that first must be mixed with a curing agent. This does allow for flexibility in designing the
actuator configuration as well as on the thickness of the films. In order to keep voltage requirements
below 6kV, a consistent film thickness of less than 200 m is desired. The compliant electrode that will
be used for the actuator is Carbon powder mixed with the silicone will create the electrode layers in
between the films.
Both of the dielectric elastomers considered for the actuator can achieve high response times.
The silicone based dielectric polymers generally have faster response times than the acrylic materials but
have less strain output. The speed of the response is based on the actuator design, the geometry, and the
material. For most actuation designs the electromechanical pressure response and time taken to get the
electrical charge on and off the electrode are generally not limiting factors. In most cases the frequency
of the actuation is limited by the natural frequency of the polymer stack and the inertial loading condition.
The stiffness of the acrylic and silicone polymers is quite low so these limitations must be investigated2.
It should be noted that up to a certain point, shortening the length of the actuator will increase the
frequency response. Because the design application for the electro active polymers is for a flapping wing
actuator on a Micro Air Vehicle the length of the actuator can be made quite small.
3.2 Power Source
Dielectric EAPs usually require a range of 1000-10000V, depending on material thickness, to
fully excite and create the elongation in the muscles necessary to be used in flapping wing applications.
The voltage required is extremely high and would seem impractical if it wasnt for the recent
miniaturization of step-up voltage converters. From the manufacturer, EMCO High Voltage Corporation,
a voltage converter of model A60P-5 was purchased. The voltage input-output is proportional, with a
0.7 V start up voltage and 5 volts to reach peak power. Totaling a weight of only 8.49 grams and a size of
2.45 cubic centimeters, the step-up voltage converter by EMCO is very feasible for use in micro air
vehicles. Smaller converters can be purchased but are significantly more expensive. Testing on the
EAPs will be done using an external power source input set at 5V. In the final product, a lithium
polymer or thin film rechargeable battery would be used as the start-up, on board power source. The
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power source can be wired to a circuit board with a switch to rapidly turn on and turn off the electric field,
which will allow the wings to be moved in a flapping motion.
3.3 Fabrication
EAPs come in many different types and arent typically commercially available in standard
configurations. Because of this, individual manufacturing processes to make the EAPs must be
developed. The capstone groups first attempt to manufacture working EAPs consisted of a rolling
technique. The process started with the BJB TC-5005 silicone base and a curing agent. Different size
metal shims were used to set the edges and height, and the silicone mixture was spread onto a Teflon
sheet using a paint spreader to fill the sheet. Two sets of thicknesses were tried, the first was 300 m
(.012 inches) and the second was 460 m (0.018 inches). After the strips of silicone were cut to size,
using the voltage transformer, multiple configurations were set up to test the EAPs for motion. Carbon
grease was applied as the electrode material. The tests performed on single layers and on stacks of films
yielded no visible results to the elastomers.
Failure was attributed mainly to a non-functioning compliant electrode layer as well to possible
impurities and inconsistencies in the polymer sheet. An additional method that was tried was involved
pressing the silicone mixture between two glass sheets, again using the metal shims to set the height.
This process was not successful due to the formation of air bubbles in the films. Following these original
fabrication methods, it was been decided to pursue a different, more controlled fabrication technique
using spray deposition, originally developed by researchers at Bristol University. When the Bristol
University team produced their working EAPs, they used an airbrush and mixed the silicone with a
solvent. They sprayed this mixture on the side of an automated, rotating disk where they had their EAP
stencils placed. This rotating disk and constant spray rate ensured uniform thickness of the silicone layer.
After the first silicone layer was sprayed, the electrode layer, composed of graphite powder and silicone
suspended in a solvent, was applied. This layered process was repeated until the desired number of layers
was reached.7
This process has numerous advantages compared to the first attempt. The first of these being,
when the layers are cured the EAP is one unit and fused together, unlike the first attempt when the layers
were only placed on top of each other with nothing to hold them together. Another advantage to this
process is the thickness of each layer can easily be controlled down to dimensions less than 100 m. This
will ensure high strains with the voltage provided. The last advantage and arguably the most important is,
with the carbon powder electrode in-between each layer, excellent conduction, and an alternating polarity
of electrical charge is obtained. This is desirable, because instead of having the charge try to go through
every layer, the charge now will only have to be felt through one thin layer of silicone. If every other
carbon layer is positive, and in between those positive layers are negatively charged layers, each silicone
layer will be acting independently with their own 4000 volt charge. However, the entire EAP will work
together because the layers were fused together. This will be an enormous improvement, and has been
shown to be a consistent and repeatable fabrication process.
This fabrication method will be closely duplicated. Time constraints limit the groups ability to
construct the automated wheel that would be essential to mass production of elastomers. However,
because of the small number of EAPs that need to be manufactured by the capstone group, the wheel will
not be necessary. The biggest concern for the technique is how to minimize variance in film thickness.
Ideally a rotating system that provides a constant angular velocity would be ideal, but this was found to
not be necessary for the production of an initial actuator. A more precise and efficient method could be
employed after the initial actuator has been shown to successfully operate.

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3.4 Spray Deposition Thickness Testing

A conservative reference for the breakdown voltage strength of silicone elastomers is 50 MV/m.
Using the EMCO voltage transformer the max output voltage achieved so far has been 4000V, which
means the film thickness limit is 80m. The design goal is for 100m, which gives a 20 tolerance or
20%. Variance tests were performed by manual means using an Accuspray Air gun. The strips produced
were cut into 1 cm sections and weighed. The percent difference in weight was considerably less than
20%, so a manual spraying method was deemed sufficient.
Various tests have been performed, aimed at identifying the necessary spraying parameters for
achieving films of 100 m in thickness. This involves varying the number of passes of the spray gun at
constant rates of spray across the length of the test area. Figure 1 below shows a thickness test in
progress:

Figures 1-a and 1-b: Demonstration of Silicone thickness test in the fume hood
The manually sprayed layers have been measured for in multiple spots using a microscope. The
microscope is calibrated by analyzing a metal shim of known thickness and measuring it using the camera
and included software attached to the microscope. Once calibrated, the experimental test thicknesses are
measured and recorded for the spraying parameters used to produce that particular film. This will allow
for the identification of the approximate linear speed, deposition height, and number of passes required to
produce films of 100 m.
3.5 EAP Testing
A completed EAP will be tested for planar expansion and bending deflection. These will be measured by
using a grid background and recorded with a camera. Expansion and deflection rate will also be tested
using a high-speed camera available to the group. Force applied by the EAP will be measured using a
strain gauge. These measurements will then be compared to equations 1 and 2 to determine the error and
allow for refinements in the manufacturing process.
In order to produce the best possible results with the manufactured EAPs, there will be a testing
procedure. Testing will involve recording the voltage requirements, expansion ratios, and generated
forces produced for various film lengths, thicknesses, number of layers, and electrode polarity
orientations of the EAPs. Also, varying the spray distance will provide for different thicknesses in each
layer. It is expected that thinner layers will produce more extension due to the silicone materials voltage
requirement. Changing the ratio of the two-part silicone mixture as well as changing the viscosity of the
silicone-solvent mixture and using different numbers of layers will also be variables to test. After the
original test, with the original variables chosen, the thickness of the layers will be changed and the
Proceedings of the 2012 ASEE North-Central Section Conference
Copyright 2012, American Society for Engineering Education

resulting change in extension will be recorded. The thickness of the layers will then be adjusted based on
the results of testing. Each variable will be tested to determine its effect on the motion of the EAP, so that
a design configuration can be optimized.

4. Discussion
4.1 Design Configurations
Two viable options for the EAP stack configurations rely on either designing a bending actuator
or an extending actuator. Both configurations would allow for the anchoring of the EAP to a centrally
located sternum and then to the wing root of the MAV. A bending type actuator would consist of 8 to 12
layers of the silicone, compliant electrode, and a transparency film. This stack would be secured to a thin
stainless steel shim (50 m) . As a result, the expanding of the silicone and electrode layers can be
constrained to bend around the transparencies and the metal shim because neither of these materials can
extend longitudinally. The end of the shim can therefore be attached to the wing root , causing rotation of
the wing about the hinge.
An extender type actuator would also consist of a number of silicone layers but without the
transparencies. An extender can be made with a high length to width ratio so that expansion is
maximized in the extension direction. An EAP attached to the wing root at an angle would rotate the
wing down when the EAP expanded , but a compression spring would most likely need to be used to snap
the wing back up around the hinge to its original position. Another option could use a tube shaped
extender rolled around a spring.
4.2 Challenges
There are a few challenges to overcome in the successful development of EAPs for use in
FMAVs. The EAPs will function and deliver the elongation and or bending that is required for this
application; however, reaching the frequency of typical MAVs will be difficult. FMAVs often operate in
the 15-30 Hz range to achieve hovering, and although EAPs are capable of even higher frequencies, large
variances in performance are expected due to material imperfections and initial frequencies may only
exhibit cycle times around 5 Hz. Further testing would need to be done to optimize the EAP
configuration and increase the frequency of the device. Another possible challenge would be limiting the
weight of the MAV. The on board power supply would consist of a 5V battery. Finding a rechargeable
lightweight battery that would still allow for sufficient flight will be a matter to address moving forward.
The material properties of silicone based dielectric elastomers are largely dependent on the
fabrication process, which can result in flawed areas on the material that can lead to dielectric breakdown
failure. As a result, producing multiple EAPs that are extremely consistent from actuator to actuator will
be difficult until a repetitive and repeatable fabrication process can be mastered. This will result in EAPs
that perform consistently.
4.3 Future Work
The original EAP fabrication failed to yield any promising results that could lead to motion with
the silicone stacked layers and carbon grease. The repetitive spraying process that includes spray
depositing the silicone elastomer followed by an electrode layer is expected to produce satisfactory
results. In order to produce a working EAP, spray parameters need to be first be finalized for producing
films at the necessary thickness. After this is determined EAP configurations can begin to be fabricated
and tested.
Proceedings of the 2012 ASEE North-Central Section Conference
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A wing structure and hinge have been designed in the 3-D modeling package, Solid Works.
Using this design it will be shown how the EAP actuation system can be implemented into the wing
structure design. A specific onboard power supply still needs to be selected to power the EAP actuators
that could be used in a future MAV. Additional work also will consist of designing the circuit board
required for switching the voltage on and off.
5. Conclusion
Originally planning on designing flapping wing actuation system for the AFRL, the Ohio
Northern Senior Mechanical Engineering capstone group decided to pursue a new technology to power an
MAVs flapping wings. Artificial muscles, in this case EAPs, offer many advantages to the world of
MAVs. The research on EAPs and using them to flap the wings of a surveillance craft is still being
conducted across the country and around the world by several graduate level programs. The AFRL would
be pleased to accept a project introducing a new idea to their MAV project. By designing and fabricating
their own artificial muscles from EAPs, the ONU design team will be able to present the AFRL with a
whole new area of possibilities and a viable alternative for MAV flapping wing actuators.

Acknowledgements
Our group would like to thank the following people for their contributions to date:

Dr. Jed Marquart: Advisor

Brad Hummel: Power Source and controls
Professor Amelia Anderson-Wile: Polymer fabrication
Dr. Hui Shen: Materials and fabrication
Professor Stuart Burgess and Seun Araromi from Bristol University: Fabrication and configuration of
polymers

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References
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