A Topology Optimization Approach to Design of a Low Cost 3D Printable Monolithic Compliant Mechanism for FWMAV’s Wing Actuation

Compliant Mechanisms, Topology Optimization and low-cost 3D printing technologies have been exploited in a combined design approach aimed at the development of a Flapping Wing Micro Air Vehicle’s wing actuation mechanism. A series of topology optimization analysis was implemented to explore four different design domains, each with a specific supports’ positioning. Subsequently, the obtained topologies were geometrically remodeled and tailored to comply with the 3D printing process parameters, resulting in several monolithic Compliant Mechanisms. The different remodeled mechanisms were finally compared in terms of stress and range of movement, through non-linear transient Fem analysis. Although the designed compliant mechanisms move at high rotation frequencies (about 25 Hz) and undergo large deflections, the obtained results are interesting with regard to maximum stresses and rotation angle amplitudes, paving the way to a future design improvement both deepening fatigue issues and implementing size and shape optimization.