The development of a flapping wing microaerial vehicle mechanism with a high strength-to-weight ratio to withstand high flapping frequency is of significant interest in aerospace applications. The traditional manufacturing methods such as injection moulding and wire-cut electrical discharge machining suffer from high cost, labour intensiveness, and time-to-market. However, the present disruptive additive manufacturing technology is considered a viable replacement for manufacturing micromechanism components. Significantly to withstand high cyclic loads, metal-based high strength-to-weight ratio flapping wing microaerial vehicle components are the need of the hour. Hence, the present work focused on the fabrication of flapping wing microaerial vehicle micromechanism components using selective laser melting with AlSi10Mg alloy. The manufactured micromechanism components attained 99% of dimensional accuracy, and the total weight of the Evans mechanism assembly is 4 g. The scanning electron microscopy analysis revealed the laser melting surface characteristics of the Al alloy. The assembled mechanism is tested in static and dynamic environments to ensure structural rigidity. Aerodynamic forces are measured using a wind tunnel setup, and 7.5 lift and 1.2 N thrust forces are experienced that will be sufficient enough to carry a payload of 1 g camera on-board for surveillance missions. The study suggested that the metal additive manufacturing technology is a prominent solution to realize the micromechanism components effortlessly compared to conventional subtractive manufacturing.
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