The bionic flapping-wing aircraft has the advantages of high flexibility and strong concealment; however, in the existing flapping-wing aircraft, the platform performance is influenced by the payload capacity, endurance, and durability; additionally, the mission capability is constrained, making it challenging to put into use in real-world scenarios. In response to this issue, this article offers a thorough design approach for a large-span flapping-wing aircraft, focusing on effective flapping wings, effective flapping mechanism design, and enhancement of flapping mechanism reliability, and ultimately realizing the design and verification of a new bionic flapping-wing aircraft with a large wingspan, called “Cloud Owl”. It has a wingspan of 1.82 m and weighs 980 g. The aircraft is capable of autonomous flight and remote control, and it can carry a range of mission-specific equipment. More than 200 flights have been made by “Cloud Owl” so far in Xi’an, Beijing, Tianjin, Tibet, Ganzi, and other places. It has evolved into a flapping-wing aircraft platform with exceptional stability, payload capacity, and long endurance.

Medium and large-sized birds exhibit remarkable agility and maneuverability in flight, with their flapping motion encompassing degrees of freedom in flapping, twist, and swing, which enables them to adapt effectively to harsh ecological environments. This study proposes a flapping–twist coupled driving mechanism for large-scale flapping-wing aircraft by mimicking the motion patterns of birds. The mechanism generates simultaneous twist and flapping motions based on the phase difference of double cranks, allowing for the adjustment of twist amplitude through modifications in crank radius and phase difference. The objective of this work is to optimize the lift and thrust of the flapping wing to enhance its flight performance. To achieve this, we first derived the kinematic model of the mechanism and conducted motion simulations. To mitigate the effects of the flapping wing’s flexibility, a rigid flapping wing was designed and manufactured. Through wind tunnel experiments, the flapping wing system was tested. The results demonstrated that, compared to the non-twist condition, there exists an optimal twist amplitude that slightly increases the lift of the flapping wing while significantly enhancing the thrust. It is hoped that this study will provide guidance for the design of multi-degree-of-freedom flapping wing mechanisms.