This is an assembly instruction of a full 3d printed ornithopter "Flying Pants". CAD data file of the parts can be freely downloaded at Thingiverse or 123dapp.com. You can also order the 3D printed parts to Shapeways or DMM.com

1. World's first?
Full 3D printable ornithopter
Assembly instruction
February 2014
Yusuke Takahashi
(Fablab Kitakagaya/The Flapping Wing Factory)

2. The ornithoper "Flying Pants" was
originally developed by author as a FABLAB
workshop item in 2013.
The original version was made of hybrid materials
such as SLS(*) printed parts and carbon rods.
SLS(Selective Laser Sintative): One of the high-end 3D printing technologies

3. In 2014, personal 3D printers are becoming
more and more affordable, so I revised the
parts design suitable to these printers.
The new design is suitable for any personal
FFF(fused filament fabrication) type 3D printers
like as Reprap, Replicator, and Cube, etc.

4. CAD data file of the parts can be freely
downloaded at Thingiverse or 123dapp.com.
Thingiverse:
http://www.thingiverse.com/thing:239789
123dapp.com:
http://www.123dapp.com/smb-123D_Design/Flying-Pants/2107482

5. You can also order the 3D printed parts to
Shapeways or DMM.com.
Shapeways:
http://www.shapeways.com/model/1693498
DMM.com:
http://make.dmm.com/item/30182/

6. Specification of "Flying Pants":
Wing span:
Length:
Weight:
Power source:
Suitable materials:
300 mm
135 mm
around 2.5 grams
medium size rubber band * 2
polyamid(SLS*) or ABS(FFF)
* Select "White Strong & Flexible" (Shapeways)
" ナイロン ( ポリアミド )"(DMM.com)
You also need a small paper clip for the crank and
a thin plastic bag for the wing membrane.

7. Step 1:
Parts check and preparation
Parts are often printed with a raft and supports.
They should be removed and cleaned up carefully.

8. Step 2:
Parts clean-up
Finish carefully!
A raft may be peeled off by hands.
Supports should be removed using cutter knives.
Parts surface can be finished by engineers files.

9. Step 3:
Assembly of the right arm and the frame
The right arm is fixed to the frame.
They are designed as snap-fit, but you can fix
them by a drop of instant glue.

10. Step 4:
Assembly of the left arm and the frame
The left arm is a moving parts.
The arm should be able to flap freely.
If it won't flap smoothly, enlarge the holes of the
arm by drills or reamers.

11. Step 5:
Making of the crankshaft
The crankshaft can be made from a small paper
clip. Bend it carefully using a needle nose plier
and cut an excess off.

12. Step 6:
Making of the crankshaft
3mm
The crankshaft can be made from a small paper
clip. Bend it carefully using a needle nose plier
and cut an excess off.

13. Step 7:
Making of the crankshaft -Finish
8mm
8mm
8mm
The crankshaft can be made from a small paper
clip. Bend it carefully using a needle nose plier
and cut an excess off.

14. Step 8:
Assembly of the crankshaft and the frame
The crankshaft is inserted into the holes of the
frame.

15. Step 9:
Assembly of the crank and the rocking arm
Slot the crank pin into the slit of the rocking arm.

16. Step 10:
Hook rubber bands
Hook a pair of rubber bands to the crank end and
the frame.

17. Step 11:
Test run
Wind the crank up about thirty times.
As the crank rewinds, the left arm will flap
bouncingly.

18. Step 12:
Cut out the wing membrane
300mm
135mm
Cut the wing membrane out from a thin plastic
bag* using cutter knives.
* film thickness < 0.01 mm would be better

19. Step 13:
Apply the wing membrane to the frame
Apply thin strips of double-sided tape to the frame.
And then apply the wing membrane carefully to
the frame along the tapes.

20. Step 14:
Assembly finished!
Assembly finished.
Bend the tail up slightly for a stable flight.
Let's take it out for test flights!

21. Step 15:
Test flight
Test flights can be made either in the room or
outdoors(in the calm, windless condition).
Apply power by winding the crank up about thirty
to fifty times.
Hold the plane by your fingers horizontally, and
push it off slightly upward,.
If the plane dive straight to the ground, bend the
tail up more or simply launch the plane upward.
If it turns sharp to right of left, bend the opposite
side of the wing chip slightly backward.

22. Some Hints of hacking the pants 1:
Painting / marking
Painting or marking on the wing is fun!
Colorful marker pens would be suited to the job.
Create your original pants.

23. Some Hints of hacking the pants 2:
Weight reduction
Cut
Cut
Carbon rod
Carbon rod
Fix by instant glue
You can upgrade the wing arms by carbon rods*.
The weight is dramatically reduced to under 2.0
grams and you can enjoy longer flight time.
* 0.7mm dia 140mm long size * 2

24. About author:
Yusuke Takahashi (Flappingwing)
Location: Osaka, Japan
A founder of The Flapping Wing Factory
Personally engaged in the development of small
ornithopters for 10 years.
Member / operating staff of Fablab Kitakagaya
Blog: http://blog.goo.ne.jp/flappingwing/
http://www.youtube.com/user/flappingwing
http://www.slideshare.net/Flappingwing/