Articulated WIngs

Meghan Carraher 29' - Kickbox 2026

Introduction:

The Kickboxer: Meghan Carraher, Mechanical Engineering Major mcarraher@elon.edu The Expertise: Sponsor:

Dr. Jonathan Su, Associate Professor of Engineering

Additional Help and Input:

Dr. Bethany Brinkman, Associate Professor of Engineering

The Project:

Building functional and wearable bird wings involving several stages:

Introduction:
Planning Phase:
Prototyping Phase:
Materials Phase:
Results:

Planning Phase:

I referenced Willow Creative for the appearance and motion of my wings. The frame design went through many prototypes, ending on a 4 foot wide open length for each wing, totaling the wingspan at around 8 feet total. This length allowed the wings to sit at a similar closed position on my back. Willow also gave material specifications, which I used to order the Linear Actuators and 12V battery. This was crucial because I do not have much electronics expertise, and I know these products work for the task and are compatible with each other. I used the small Kickbox notebook for all my sketches, ideas, brainstorming, measurements, and calculations. Documentation and photographs were essential to keep the design in order and allow successful project progression.

Figure 1: My inspiration, reference, and source for parts.

Prototyping Phase:

I built 6 prototypes, 5 from foam board and 1 from cardboard, before I finalized my frame dimensions. Each gave insights to the motion of the frame and how it worked, the order of assembly, size, and scaling. When prototyping, it is essential to take notes and only make one change at a time between prototypes. This makes it possible to identify the exact effect a change has on the design. The foam versions were cut to length and secured at the joints with a rod of toothpick that allowed the strut to rotate around it. I also cut a paperclip into short segments for the joints on the first prototype. The joints were secured with hot glue on the outer edges; the center needed to be free for movement. The cardboard version was the same concept, except secured using brass fasteners instead.

Tools used:

Ruler
Tape Measure
Cutting Mat
Exacto Knife
Push Pin (for making joint holes)
Hot Glue
Box Cutter (for cardboard)
Drill (cardboard joint holes)

The full-size cardboard version was based off the scaled dimensions from a mid-size prototype. I then experimented more with the full-size prototype to determine where I needed to mount the actuator for the optimal range of motion, and finalize the actuator size. It is very important to SECURE THE PROTOTYPE when taking measurements. This prevents shifting that will throw the measurements off.

Figure 2-4: Foam prototypes and the full-size cardboard prototype, secured with tape for actuator experimentation.

Materials Phase:

Willow used aluminum tubes for her frame, since the metal is strong but relatively light. This is very important for a backpack mounted device like this one, since the weight needs to be manageable to wear. I used Aluminum Channel Trim instead, since it was easier to obtain and sold in sections that could be cut to length. I also had considered adding LEDs to the frame, and the open channel would provide a space to run the lights. The final dimensions were "channel trim for 5/8" plywood," or 5/8" interior channel trim. This material is frequently used to cap plywood and glass, hence the measurements for the interior width. 5/8" interior channel trim was selected after I ordered the actuators and could physically examine and compare them to sample widths of trim. This width allowed the actuator's mounting bracket to sit comfortably on top, and would provide the best strength to hold the weight of both the frame and the actuator.

Figure 5-7: The specification sheet for the actuator and the sample channel trim pieces of varying widths.

Results:

I obtained all my materials and received MakerHub and Prototype Lab training for the bandsaw and drill press I would need to cut and drill the metal for assembly. I was not able to build the final frame out of metal, set up a backpack, and assemble all the electronics needed, but I have the plans and measurements needed to fully complete the project at a later date.

Figure 8-10: The vision for the frame as a backpack, and the final frame prototype.

Figure 11-13: A leaf blower backpack for reference, the actuator placement, and a reverse polarity switch to control the direction of motion once attached in the circuits.

I learned a ton about networking, designs, measurements, and even about how to manage my workload as an engineering student. I achieved one of my main goals, which was to receive shop training for a few of the tools. The most difficult parts of working on this project included finding the right materials for specific functions, time management, and electronics. Dr. Su, Dr. Brinkman, and Cassidy gave me amazing advice, input, (and parts) on my project. I enjoyed this teamwork aspect of the project, and it showed me how invaluable second opinions are to the success of a goal. Laymen input from my father and family was also hugely helpful, since their questions and suggestions helped me understand my design and goals even better and realize where I was falling short.

Overall, I had a ton of fun working on these wings and taking charge of the engineering process in a very personal way. My goals are to finish the metal frame in full, modify a backpack, and discover which parts and knowledge I need to implement the electronics. Once I connect the backpack, frame, and electronics, I can get to the fun part- covering my work with feathers!