3D printed feathers with embedded aerodynamic sensing

Bird flight is often characterized by outstanding aerodynamic efficiency, agility and adaptivity in dynamic conditions. Feathers play an integral role in facilitating these aspects of performance, and the benefits feathers provide largely derive from their intricate and hierarchical structures. Although research has been attempted on developing membrane-type artificial feathers for bio-inspired aircraft and micro air vehicles (MAVs), fabricating anatomically accurate artificial feathers to fully exploit the advantages of feathers has not been achieved. Here, we present our 3D printed artificial feathers consisting of hierarchical vane structures with feature dimensions spanning from 10^-2to 10²mm, which have remarkable structural, mechanical and aerodynamic resemblance to natural feathers. The multi-step, multi-scale 3D printing process used in this work can provide scalability for the fabrication of artificial feathers tailored to the specific size requirements of aircraft wings. Moreover, we provide the printed feathers with embedded aerodynamic sensing ability through the integration of customized piezoresistive and piezoelectric transducers for strain and vibration measurements, respectively. Hence, the 3D printed feather transducers combine the aerodynamic advantages from the hierarchical feather structure design with additional aerodynamic sensing capabilities, which can be utilized in future biomechanical studies on birds and can contribute to advancements in high-performance adaptive MAVs.