My Final Project:
FantasyFlare - Animatronic Cosplay Wings
“If birds can glide for long periods of time, then… why can’t I ?” -Orville Wright
How I generated the idea of doing an animatronic wing Flapping for Final Project .
I noticed people are very eager to take photos with background images of bird wings.
This showed me the strong visual and emotional appeal of appearing to have wings.
Instead of a static background, I wanted to create something dynamic and wearable.
So, I decided to build a wing flapping animatronic mechanism mounted on the back of my shoulders.
This would give the illusion of real, moving wings attached to a person.
The idea adds a unique, interactive element to photos and public appearances.
Mechanically, it involves lightweight linkages, servo motors, and synchronized motion control.
The design must be ergonomic, safe, and visually impressive.
This wearable animatronic blends cosplay, robotics, and artistic expression.
It became the centerpiece of my final project, combining creativity and engineering skill.
Inspiration from Nature: I have always been fascinated by the natural movement and behavior of birds—their wings, head motions, and vocalizations.
Passion for Mechanics and Motion: As a mechanical student, I wanted to apply principles of kinematics and linkages to replicate realistic bird-like motion.
Interest in Robotics and Automation: I was interested in integrating mechanical systems with electronics and programming for motion control.
Challenge of Realism: I was intrigued by the challenge of making lifelike movement, which requires precise control over motors and linkages.
Exposure to Animatronics: I came across animatronic characters in movies, museums, and theme parks, which sparked the idea of combining
engineering with entertainment.
Scope for Multidisciplinary Work: The project allowed integration of mechanical design, embedded systems, and artistic modeling — ideal for showcasing
all-round skills.
Feasibility: After evaluating complexity, resources, and cost, I found that a bird model (smaller scale) was a feasible yet impressive animatronic application.
Innovation Element: While animatronics exist, building a lightweight, customizable bird with open-source components added uniqueness.
Engagement and Visual Appeal: Birds are universally appealing, making the project interesting to audiences in both technical and non-technical domains.
Long-Term Use: I also saw future applications in educational models, museum exhibits, or themed installations — making it more than just a student project.
Animatronic articulated cosplay wings are a fantastic project that blends mechanics, electronics, and cosplay aesthetics. Since Iam already have experience in mechanical fabrication, electronics, and control systems,I can design an advanced wing system with smooth articulation and lightweight yet durable materials.
Wing Mechanism Type:
Scissor Mechanism: Simple, reliable, and effective for controlled extension and retraction.
Linear motion by d.c motor
Materials:
Fabrication Parts Frame 750mm *300mm rectangular frame Own Fabrication For Wings Aluminium Flat bar 20mm*6*100
Super Smooth Hard Chrome plated 12mm diameter carbon steel rod 1000mm long
Learn more about our products https://robu.in
.Ball screw rod
Ball Screw Rod 1204 - 12mm Dia. of 1000mm length (with end machining) with SFU1204 Flange Nut Combo
https://robokits.co.in/mechanical-parts/ball-screw-accessories/astro-ball-screw-rod-1204-12mm-dia.-of-1000mm-length-with-end-machining-with-sfu1204-flange-nut-combo?srsltid=AfmBOoqW3rzqupmTkr0HY-sBMejOfYAs10m-I3sRcPIlLbAEjZ4oKSli
linear Bearing SC12UU 12 mm Linear Ball Bearing Slide Unit CNC 3D Printer
https://robu.in/product/sc12uu-12-mm-linear-ball-bearing-slide-unit-cnc-3d-printer-scs12uu/?gad_source=1&gclid=Cj0KCQjwqIm_BhDnARIsAKBYcmuxj8O9at8nKjRdz3htc voxNrL_v0DHb2AZx_0rjTozlriwuFqY3xYaAlZsEALw_wcB
shaft holder
SK12 12MM linear bearing rail support XYZ Shaft Table CNC Router SH12A
https://robu.in/product/sk12-12mm-linear-bearing-rail-support-xyz-shaft-table-cnc-router-sh12a/?gad_source=1&gclid=Cj0KCQjwqIm_BhDnARIsAKB YcmtMQdVvAvtMyoOTpT1XEtghgGvexqdOHUdvJhJ595RwJXS7k8dRse4aAvJIEALw_wcB
Motor to Shaft Couple
Flexible Coupling 8mm
https://robu.in/product/flexible-coupling-enclasp-metel-bellow-coupling-od25mm-x-l32mm-bore8x8mm-zrb-25x32/?gad_source=1&gclid=Cj0KCQjwqIm_BhDnARIsAKBYcmuQ_6QhBjekuEujkQ2fMOLG92IjwteyFzmxn2Woa2KwEY3_t9ldo_8aAptlEALw_wcB
thrust bearing
https://in.rsdelivers.com/product/skf/51306/skf-51306-thrust-ball-bearing-open-type-30mm-id-od/2076310
Electrical
Motor
D8MM Shaft 12V 10RPMMIN High Torque Brushless DC Worm Gear Reduction Motor
https://zbotic.in/product/d8mm-shaft-5840-31zy-12v-10rpm-min-high-torque-brushless-dc-worm-gear-reduction-motor/?gad_source=1&gclid= Cj0KCQjwqIm_BhDnARIsAKBYcmv_P33oGYJJRvdRAFP3s7uK96czA-YQgAqSZoAgEbrfLAOSYZySo5caAitCEALw_wcB
BATTERY 12 VOLT
< https://robu.in Bluetooth module to operate using Cell Phone.
Wire etc
ELectronics
D.c relay switch to cutoff.
Motor driver for foward reverse switch. L298N 2A Based Motor Driver Module
https://robu.in
Ardiuno or alternative
Ardiuno or alternative https://robu.in Bluetooth module to operate using Cell Phone.
Ardiuno or alternative https://robu.in Bluetooth module to operate using Cell Phone.
limitswitch
>Bill of Material
| Product Name | Description | Price | Quantity | Total Price |
|---|---|---|---|---|
| squre pipe mild steel | 10 feet | ₹50 per feet | 1 piece | ₹500/- |
| Aluminium Flat Bar | 20mm*6mm*100mm | ₹100/- | 6 piece in 100mm | ₹600/- |
| Hard Chrome plated rod | 12mm rod | ₹969.00 | 6 piece in 100mm | 5,814/- |
| Ball screw rod | 12mm Dia. of 1000mm length | ₹3,519.94/- | 1 piece in 100mm | 3,519.94/- |
| linear Bearing | 12mm Dia Slide Unit | ₹121.00/- | 2 piece in 100mm | ₹242/- |
| shaft holder | 12MM linear bearing rail support | ₹65.00/- | 2 piece in 100mm | ₹260/- |
| Motor to Shaft Couple | Flexible Coupling 8mm | ₹377.00 /- | 1 piece | ₹377.00 /- |
| Thrust bearing | Thrust Ball Bearing (ID-6mm, OD-12mm, TH-4.5mm) | ₹129.00 /- | 6 pieces | ₹774.00 /- |
| D.C Motor | D8MM Shaft 12V 10RPM | ₹1,814.84 /- | 1 pieces | ₹₹1,814.84 /- |
| BATTERY | 12V | ₹1,9994 /- | 1 pieces | ₹1,999 /- |
| wire | 14/36 Multi Colour DC Wire Cable | ₹235/- | 1 pieces | ₹235 /- |
| D.c limit switch | to cutoff. Motor | ₹47/- | 2 pieces | ₹94 /- |
| Motor driver | for foward reverse switch | ₹881.00/- | 1 pieces | ₹881.00 /- |
| Motor driver | L298N Based Motor Driver Module 2A | ₹150/- | 1 pieces | ₹150 /- |
| For Wings | foam,polycarbonate,glue,color etc | ₹250/- | 4 pieces | ₹1000 /- |
| Grand Total | ₹18,260.78 /- |
Button-Based: switch push-button as well asbluetooth Remote Switch.
. Wing Motion Programming Logic
Basic Code Flow (For ESP32)
1.Fully Extended MoTion (Gliding Mode)
Usually wing will be closed when remote on the the motor let the setup to move up and the relay will be off in the wing open position.
Only 2 relay
2.Flapping Motion (Dynamic Motion)
when remote on the the motor let the setup to move up and the top relay will be off in the wing open position and return to bottom relay
after cut of it move up and down continuously
System integration This part is documented in thesystem integration week.