Programmable matter is a material whose properties can be programmed to achieve specific shapes or stiffnesses upon command. This concept requires constituent elements to interact and rearrange intelligently in order to meet the goal. This paper considers achieving programmable sheets that can form themselves in different shapes autonomously by folding. Past approaches to creating transforming machines have been limited by the small feature sizes, the large number of components, and the associated complexity of communication among the units. We seek to mitigate these difficulties through the unique concept of self-folding origami with universal crease patterns. This approach exploits a single sheet composed of interconnected triangular sections. The sheet is able to fold into a set of predetermined shapes using embedded actuation. To implement this self-folding origami concept, we have developed a scalable end-to-end planning and fabrication process. Given a set of desired objects, the system computes an optimized design for a single sheet and multiple controllers to achieve each of the desired objects. The material, called programmable matter by folding, is an example of a system capable of achieving multiple shapes for multiple functions.

Insect- and bird-size drones—micro air vehicles (MAV) that can perform autonomous flight in natural and man-made environments are now an active and well-integrated research area. MAVs normally operate at a low speed in a Reynolds number regime of 10 ⁴ –10 ⁵ or lower, in which most flying animals of insects, birds and bats fly, and encounter unconventional challenges in generating sufficient aerodynamic forces to stay airborne and in controlling flight autonomy to achieve complex manoeuvres. Flying insects that power and control flight by flapping wings are capable of sophisticated aerodynamic force production and precise, agile manoeuvring, through an integrated system consisting of wings to generate aerodynamic force, muscles to move the wings and a control system to modulate power output from the muscles. In this article, we give a selective review on the state of the art of biomechanics in bioinspired flight systems in terms of flapping and flexible wing aerodynamics, flight dynamics and stability, passive and active mechanisms in stabilization and control, as well as flapping flight in unsteady environments. We further highlight recent advances in biomimetics of flapping-wing MAVs with a specific focus on insect-inspired wing design and fabrication, as well as sensing systems. This article is part of the themed issue ‘Moving in a moving medium: new perspectives on flight’.

As the characteristic size of a flying robot decreases, the challenges for successful flight revert to basic questions of fabrication, actuation, fluid mechanics, stabilization, and power, whereas such questions have in general been answered for larger aircraft. When developing a flying robot on the scale of a common housefly, all hardware must be developed from scratch as there is nothing ‘off-the-shelf’ which can be used for mechanisms, sensors, or computation that would satisfy the extreme mass and power limitations. This technology void also applies to techniques available for fabrication and assembly of the aeromechanical components: the scale and complexity of the mechanical features requires new ways to design and prototype at scales between macro and microeletromechanical systems, but with rich topologies and material choices one would expect when designing human-scale vehicles. With these challenges in mind, we present progress in the essential technologies for insect-scale robots, or ‘pico’ air vehicles.

The effect of wing flexibility in hoverflies was investigated using an at-scale mechanical model. Unlike dynamically-scaled models, an at-scale model can include all phenomena related to motion and deformation of the wing during flapping. For this purpose, an at-scale polymer wing mimicking a hoverfly was fabricated using a custom micromolding process. The wing has venation and corrugation profiles which mimic those of a hoverfly wing and the measured flexural stiffness of the artificial wing is comparable to that of the natural wing. To emulate the torsional flexibility at the wing-body joint, a discrete flexure hinge was created. A range of flexure stiffnesses was chosen to match the torsional stiffness of pronation and supination in a hoverfly wing. The polymer wing was compared with a rigid, flat, carbon-fiber wing using a flapping mechanism driven by a piezoelectric actuator. Both wings exhibited passive rotation around the wing hinge; however, these rotations were reduced in the case of the compliant polymer wing due to chordwise deformations during flapping which caused a reduced effective angle of attack. Maximum lift was achieved when the stiffness of the hinge was similar to that of a hoverfly in both wing cases and the magnitude of measured lift is sufficient for hovering; the maximum lift achieved by the single polymer and carbon-fiber wings was 5.9 × 10²μN and 6.9 × 10²μN, respectively. These results suggest that hoverflies could exploit intrinsic compliances to generate desired motions of the wing and that, for the same flapping motions, a rigid wing could be more suitable for producing large lift.

Unlike other flying insects, the wing motion of swallowtail butterflies is basically limited to flapping because their fore wings partly overlap their hind wings, structurally restricting the feathering needed for active control of aerodynamic force. Hence, it can be hypothesized that the flight of swallowtail butterflies is realized with simple flapping, requiring little feedback control of the feathering angle. To verify this hypothesis, we fabricated an artificial butterfly mimicking the wing motion and wing shape of a swallowtail butterfly and analyzed its flights using images taken with a high-speed video camera. The results demonstrated that stable forward flight could be realized without active feathering or feedback control of the wing motion. During the flights, the artificial butterfly's body moved up and down passively in synchronization with the flapping, and the artificial butterfly followed an undulating flight trajectory like an actual swallowtail butterfly. Without feedback control of the wing motion, the body movement is directly affected by change of aerodynamic force due to the wing deformation; the degree of deformation was determined by the wing venation. Unlike a veinless wing, a mimic wing with veins generated a much higher lift coefficient during the flapping flight than in a steady flow due to the large body motion.