Final Project: Animatronic Flapping Wing System
What does it do?
The project simulates realistic bird-like wing flapping using a wearable mechanism controlled via a WiFi-enabled ESP32 board.
Who’s done what beforehand?
Several makers have attempted servo-based wings, but i integrate custom fabrication, wireless control, and embedded electronics.
What did you design?
- Mechanical wing frame
- Actuator mount
- Wearable harness
- Custom PCB
- Control interface
What sources did you use?
- Fab Academy archive
- ESP32 datasheets
- KiCad Fab libraries
- Mechanical linkage studies
- YouTube builds
What materials and components were used?
- D.c 12v 30 rpm motor
- electric casing pipe
- PLA
- Mild steel
- Foam feathers
- ESP32
- L298N driver
- Linear actuators
- 12V battery
Where did they come from?
- Local hardware and FabLab stock
- Online stores (Robu.in, Amazon)
- New battery
How much did they cost?
Bill of Material
| Product Name | Description | Price | Quantity | Total Price | |
|---|---|---|---|---|---|
| Square Pipe (Mild Steel) | 10 feet | ₹50/ft | 1 | ₹500 | |
| Motor to screwrod Coupler | 16mm | ₹377 | 1 | ₹377 | |
| DC Motor | 12V 30RPM | ₹350 | 1 | ₹350 | |
| Battery | 12V 7 amps | ₹750 | 1 | ₹750 | |
| Battery case in sheet metal | lasercut charges | ₹500 | 1 | ₹500 | |
| Wire | 14/36 Multi Color | ₹100 | 1 | ₹100 | |
| Limit Switch | DC Motor Cutoff | ₹100 | 2 | ₹200/ | |
| Motor Driver | Manual Direction | ₹180 | 1 | ₹180 | |
| Motor fixture | 1.5inch Pipe clamp | ₹10 | 1 | ₹10 | |
| Wing Materials | Electric casing pipe 20 feet. | 1 feet ₹8 | 20 | ₹160 | |
| Rgb Led | 10feet | ₹500 | 1 | ₹881 | |
| bag belt,lock,rivit etc | 5meter,1,24no | 350 | 1 | ₹350 | |
| 2 inch,1 inch bolt,nut,washer | 24 no | 80 | 1 | ₹80 | |
| Grand Total | ₹4,438 | ||||
What parts and systems were made?
- 3D-printed joints and supports
- Mild steel pipe weld frame
- Metal Laser-cut sheet metal Battery cover
- CNC-bent Battery cover
- Custom PCB board for ESP32 + L298N
What processes were used?
- 2D Design
- 3D Modeling
- Metal Laser Cutting
- welding
- lathe work
- 3D Printing
- PCB Milling
- Embedded Programming
- Soldering
- Web Development
What questions were answered?
- How to ensure symmetric motion using actuators?
- How to integrate WiFi control with wearable mechanics?
What worked? What didn’t?
- Worked: Mechanical motion, web-based control, actuator strength
- Didn’t: D.c motor torque limitations, PCB v1 noise (solved with capacitor)
How was it evaluated?
- Peer testing
- Mentor reviews
- Usability feedback
- Live performance demo
What are the implications?
Foundation for wearable animatronics in entertainment, theater, and education.
Linked from this page to any weeks that you worked on your final project
Project Slide
Project Video
Acknowledgment
I would like to express my sincere gratitude to all those who supported and contributed to the successful completion of this project.
- Global Instructor – Santi Fuentemilla: I sincerely thank the global instructors for helping me understand the importance of Git, which transformed the way I manage and document my work. His guidance enabled me to adopt version control and maintain an organized, efficient workflow.
- Local Evaluation – Sumit Thakare: I sincerely thank my local instructor for providing continuous support and a clear overview of the Fab Academy process. His guidance helped me understand each week's assignments and stay on track throughout the journey.
- Suhas Labade: I heartfully thank Suhas Labade for providing me with the master plan to successfully complete the Fab Academy. His guidance and strategic approach were instrumental in helping me stay focused and finish the journey effectively.
- Charath and Meera Madam: I heartfully thank Charath and Meera Madam for giving me the opportunity to be a part of the Fab Academy. Their support and trust laid the foundation for this enriching learning experience.
- Charath helped in Parametric design and in 3d printing.
- Vrushab: I am deeply grateful to Vrushab for his unwavering support and help throughout my Fab Academy journey. His contribution was so valuable that words of thanks alone could never truly repay him.
- Vrushab: helped in pcb design and pcb board making.
- Manikandan (Trichy Fab Lab): I would like to thank Manikandan from Trichy Fab Lab for his dedicated support, guidance, and hands-on assistance throughout my Fab Academy journey. His expertise and willingness to help made a significant difference in completing my assignments successfully.
- Other Lab Friends – Sabareesh, Mukesh, and Nandhalal: I would also like to thank friends from other Fab Labs, especially Sabareesh, Mukesh, and Nandhalal, for their constant support, knowledge sharing, and encouragement. Their collaboration and insights added great value to my Fab Academy experience.
- My Brothers – Hari, Sundar, Viramani, and Ilamkumaran: My heartfelt thanks to my brothers for their unwavering support throughout my Fab Academy journey.
- My Brothers Sundar, Viramani helped in electronics design,Input,Output,networking,Interface assignments.
- My Brother Hari helped me in various activities such as capturing photos while I worked, assisting with tasks, and supporting me in video capturing and editing for my final project.
File download here
finalprojectboard.zipFlaping wings.zip
Bird Fly Use Arduino ESP32.pdf
batterycover.dxf