Modular and Scalable Fabrication of Insect-Scale Aerial Robots toward Demonstrating Swarm Flights

Insects can navigate in cluttered spaces and perform challenging functions such as pollination and collective object transport. By exploiting scaling laws and bioinspired designs, insect-scale micro-aerial-vehicles (MAVs) have demonstrated impressive flight capabilities such as in-flight collision resilience and acrobatic maneuvers. However, existing subgram MAVs are difficult to design, construct, and repair. Coupled with challenges in robot sensing and control, existing subgram MAVs have not achieved insect-like swarm flight, which limits potential studies of swarm behaviors and future applications such as collective sensing. Herein, a new design and fabrication method is developed to substantially improve the fabrication scalability of subgram MAVs. Based on a small set of design parameters, an automated algorithm generates the laser cut files of microrobotic components. To reduce fabrication and assembly time, stereolithographic 3D printing is used for making static components such as the airframe and connectors. The modular design enables straightforward assembly and repair, which reduces the overall fabrication time by over 2 times. Owing to the ease of fabrication and good reliability, two subgram MAVs demonstrate controlled hovering flight and coordinated lifting of an object. This result lays the foundation for future robotic studies of collective insect flight.