Robot Dragonflies: How Ornithopter Drones Fly!
Adam Savage interviews Michael, who maintains flying ornithopter drones used in Cirque du Soleil's show Echo. These 86-gram wing-flapping drones face constant maintenance challenges due to their extreme fragility and weight constraints.
Summary
In this technical discussion, Adam Savage explores the fascinating world of ornithopter drones used in Cirque du Soleil's theatrical production Echo with maintenance technician Michael. These drones are unique in the entertainment industry because they fly using flapping wings rather than traditional propellers, making them true ornithopters. Weighing only 86 grams (4 oz), the drones face extreme engineering constraints where every gram matters for flight capability.
The show employs five drones simultaneously, each piloted by separate operators including three artists and two technicians. The extreme fragility of these devices creates significant operational challenges - wings frequently break from the constant flapping motion or handling, carbon fiber frame rods snap under pressure, and the foam bodies crack, particularly in the neck and sternum areas where crashes typically occur. Battery life is critically short, lasting only about three minutes per flight.
Audience interaction presents an unexpected challenge, with spectators attempting to grab the drones during every show, often damaging them due to their surprising fragility. The maintenance team has developed extensive pre-show inspection protocols focusing on batteries, wing integrity, and structural soundness, with pilots conducting test flights to select their preferred units.
Michael's team is actively engaged in research and development to become more self-sufficient, experimenting with vacuum forming and 3D printing replacement parts. They've discovered that while they can't completely replace the lightweight foam construction, they can reinforce high-impact areas with plastic while maintaining the critical weight requirements. The brief but impactful moment in the show - where a performer releases a drone that flies away in darkness - requires hours of behind-the-scenes maintenance work to achieve the magical theatrical effect.
Key Insights
- Michael explains that these entertainment drones are unique because they fly via wing flapping rather than propellers like traditional helicopter-style drones
- Michael reveals that audience members attempt to grab the flying drones during every single show, often damaging them because people don't understand how fragile they are
- Michael describes that the 86-gram weight constraint is so critical that adding repair materials like glue or foam patches can prevent the drones from flying
- Michael explains that five separate human pilots control the drones using controllers, with no automation, creating consistency challenges when different operators rotate between shows
- Michael's team discovered through testing that they can double the weight of the drone body and it will still fly sporadically, giving them parameters for their R&D efforts
Topics
Full transcript available for MurmurCast members
Sign Up to Access