Whirligig, Hummingbird.

As I've previously mentioned, my wife loves hummingbirds. By happenstance, after completing my previous two whirligig models, a Youtube follower asked if I could convert my previous hummingbird electric motor driven model into a whirligig. So I created this model, "Whirligig, Hummingbird", for my wife (of course!).

The model design incorporates components from my previous hummingbird models and universal joints from my previous propeller boat models, but also required some new components that I had not previously designed such as a face gear. The model performs two wind driven motions; the first being that the model follows an arched motion fore and aft allowing the humming bird beak to enter and exit a "flower", and the second motion being that of the flapping humming bird wings during the arched motion. The worm gear drive provides sufficient torque to generated the fore and aft motion of the hummingbird, and for the face gear 4:1 gear ratio that provides four wing flaps per fore and aft motion.

I 3D printed this model in Tough PLA and while Tough PLA is somewhat weather resistant, I recommend occasional outdoor use in dry windy conditions.

As usual, I probably forgot a file or two or who knows what else, so if you have any questions, please do not hesitate to ask as I do make plenty of mistakes.

Designed using Autodesk Fusion 360, sliced using Ultimaker Cura 4.12.1, and 3D printed in Tough PLA on Ultimaker S5s and an Ultimaker 3e.

• Thick cyanoacrylate glue.

I acquired the following parts:

• One 16mm diameter ball bearing.
• One M8 by 1.25 threaded rod.
• One M8 by 1.25 nut.
• Two F688ZZ flanged bearings (5mm thick, 16mm outside diameter, 8mm inside diameter).

I 3D printed the following parts using Tough PLA at .15mm layer height, 20% infill and no supports:

• One "Arm.stl".
• Three "Axle (M8 by 1.25 by 4.4).stl".
• One "Axle (M8 by 1.25 by 28).stl".
• Pne "Axle Gear Crown.stl".
• One "Axle Gear Worm Screw.stl".
• Two "Axle, Shoulder Pivot.stl".
• Two "Axle, Wing Pivot.stl".
• One "Base.stl".
• One "Bearing Mount.stl".
• One "Body Left.stl".
• One "Body Right.stl".
• Two "Bolt (M8 by 1.25 by 12).stl".
• Two "Bolt (M8 by 1.25 by 22mm).stl".
• One "Bolt, Gear, Crown.stl".
• Two "Connecting Rod.stl".
• One "Drill Guide.stl".
• One "Flower.stl".
• One "Gear and Yoke (1.5m 12t).stl".
• One "Gear Face (1.5m 48t).stl".
• One "Gear Mount.stl".
• One "Gear Worm Screw.stl".
• One "Gear Worm.stl".
• Two "Gear, Crown (1.5m 12t)).stl".
• One "Hummingbird Mount Arm.stl".
• One "Hummingbird Mount Base.stl".
• Two "Journal, Cross.stl".
• One "Mount.stl".
• One "Propeller.stl".
• Two "Shoulder Pivot.stl".
• One "Stem.stl".
• Two "Wheel.stl".
• Two "Wing Bolt.stl".
• One "Wing Left.stl".
• Two "Wing Pivot.stl".
• One "Wing Right.stl".
• Two "Yoke Arm Guide.stl".
• One "Yoke Arm.stl".
• Four "Yoke.stl".

This is a high precision 3D print and assembly model using at times very small precision parts in very tight spaces. Prior to assembly, test fit and trim, file, sand, polish, etc. all parts as necessary for smooth movement of moving surfaces, and tight fit for non moving surfaces. Depending on you printer, your printer settings and the colors you chose, more or less trimming, filing, sanding and/or polishing may be required. Carefully file all edges that contacted the build plate to make absolutely certain that all build plate "ooze" is removed and that all edges are smooth. I used small jewelers files and plenty of patience to perform this step.

The model also uses threaded assembly thus an M8 by 1.25 tap and die will assist with thread cleaning if necessary.

To assemble the base, I performed the following steps:

• Pressed the two bearings into the bearing towers in "Base.stl".
• Positioned "Gear Worm Screw.stl" between the worm screw towers in the base assembly then secured in place with "Axle Gear Worm Screw.stl".
• Slid "Propeller.stl" through the two bearings then threaded it into the worm gear screw.
• Positioned "Gear Worm.stl" onto the base assembly, then secured in place with "Gear Face (1.5m 48t).stl".
• At this point, I spun the propeller to make certain the mechanism operated with ease.
• Connected "Gear and Yoke (1.4m 12t).stl" to one "Yoke.stl" using one "Journal, Cross.stl" making certain the assembly pivoted with ease.
• Secured the gear and yoke assembly to "Gear Mount.stl" using one "Axle (M8 by 1.25 by 4.4).stl".
• Slid both "Yoke Arm Guide.stl" onto "Yoke.stl", one on each end.
• Positioned the yoke assembly onto the base assembly then secured the yoke assembly and gear mount assembly to the base assembly using two "Bolt (My by 1.25 by 12).stl".
• At this point, I spun the propeller to make certain the mechanism operated with ease.
• Attached "Arm.stl" to the yoke arm using one "Axle (M8 by 1.25 by 4.4).stl".
• Attached the arm assembly center point to the base assembly arm tower using one "Axle (M8 by 1.25 by 4.4).stl".
• Assembled a universal joint assembly using two "Yoke.stl" and one "Journal, Cross.stl" then threaded "Axle (M8 by 1.25 by 28).stl" into one of the yokes..
• Threaded the free end of the axle into the yoke threads gear and yoke assembly.

To assemble the hummingbird, I performed the following steps.

• Glued "Hummingbird Mount Arm.stl" into the mount arm cavity in "Hummingbird Mount Base.stl" such that it was flush with the top of the cavity.
• Inserted "Bolt Gear Crown.stl" into one "Gear, Crown (1.5m 12t).stl", then slid the assembly into the mount base assembly.
• Glued "Body, Left.stl" into the left cavity of the mount base assembly such that it was perpendicular to the mount base assembly and flush with the bottom of the mount base assembly.
• Slid the remaining "Gear, Crown (1.5m 12t).stl" onto "Axle Gear Crown.stl", slid the assembly into the axle hole in the left body, and secured in place with one "Wheel.stl".
• Slid the free end of the axle assembly into the axle hole in "Body, Right.stl" then glued the right body to the mount base assembly such that it was perpendicular to the mount base assembly, flush with the bottom of the mount base assembly, and parallel to body left.
• Threaded the remaining "Wheel.stl" onto the free end of the axle assembly, adjusted the wheels such that the connect rod balls aligned, then secured the wheels using small dots of glue.
• Snapped one "Connecting Rod.stl" onto the connecting rod ball of one "Shoulder Pivot.stl".
• Secured the shoulder pivot assembly to one "Wing Pivot.stl" using one "Axle, Wing Pivot.stl".
• Snapped the free end of the connecting rod to the left wheel ball.
• Secured the shoulder pivot assembly to the mount base assembly left wing pivot hole using one "Axle, Wing Pivot.stl".
• Secured "Wing Left.stl" to the left shoulder pivot assembly using one "Wing Bolt.stl".
• Repeated the previous five steps for the right wing assembly.
• At this point, I spun the propeller to make certain the mechanism operated with ease.

For final assembly I performed the following steps:

• Threaded 80mm length of thread rod into "Bearing Mount.stl"
• Threaded the nut onto the threaded rod tightly against the bearing mount to secure the threaded rod into position.
• Placed the ball bearing into the bearing mount cup.
• Attached the hummingbird assembly to the arm of the base assembly using "Axle (M8 by 1.25 by 4.4).stl".
• Threaded the free universal joint to the hummingbird assembly gear crown bolt.
• Pressed "Stem.stl" into "Mount.stl" such that the curved end of the stem is closest to the mount column, and the flat end of the stem is centered over the hole furthest from the mount column.
• Pressed "Flower.stl" onto the free end of the stem.
• Positioned the mount and stem assembly over the worm gear screw side of the base assembly, then secured it to the base assembly using two "Bolt (M8 by 1.25 by 22mm).stl".

With assembly complete, I placed the bearing mount assembly into a vice, slid the hummingbird assembly onto the bearing mount assembly, then directed a fan onto the model for testing. When I was satisfied with the smooth movement of all components of the model, I used small dots of glue to hold the threaded components in the desired positions.

And that is how I 3D printed and assembled "Whirligig, Hummingbird".

I hope you enjoyed it!

The part "Drill Guide.stl" is what I used to drill a centered hole in the mounting poles for my whirligigs. I've attached a video of how I designed and used the drill guide to create the centered holes.

I used a 6 foot section of 1 5/16" diameter poplar pole. I recommend painting the pole to preserve it in bad weather.