Optimal Processing Parameters of Transmission Parts of a Flapping-Wing Micro-Aerial Vehicle Using Precision Injection Molding

In this study, we designed and fabricated transmission parts for a flapping-wing micro-aerial vehicle (FW-MAV), which was fabricated by precision injection molding, and analyzed its warpage phenomena. First, a numerical simulation (Moldflow) was used to analyze the runner balance and temperature, pressure, and stress distributions of the base, gears, and linkage of the transmission structures in an FW-MAV. These data were then applied to fabricate a steel mold for an FW-MAV. Various process parameters (i.e., injection temperature, mold temperature, injection pressure, and packing time) for manufacturing transmission parts for the FW-MAV by precision injection molding were compared. The Taguchi method was employed to determine causes of warpage in the transmission parts. The experimental results revealed that the causes of warpage in the transmission parts were, in order of importance, the mold temperature, injection pressure, packing time, and injection temperature. After the transmission parts were assembled on the FW-MAV, experiments revealed that the MAV could achieve a flight time of 180 s. Mass production of the FW-MAV by precision injection molding could potentially produce substantial savings in time, manpower, and cost.