Design and Development of a Lightweight Foldable Robotic Arm with Straight-Line Motion for UAV Manipulation

Unmanned aerial vehicles (UAVs) are widely used for monitoring and payload transport; however, their application in autonomous physical interaction remains limited due to payload constraints, stability challenges, and the complexity of integrating manipulation systems. This study presents the design and development of a lightweight foldable robotic arm based on the ten-bar Kempe Kite Inversor II linkage for UAV aerial manipulation. The mechanism generates precise straight-line motion using a single degree of freedom. Kinematic modeling and simulation validated a maximum end-effector reach of approximately 0.42 m. Structural optimization using additive manufacturing and honeycomb cellular architectures significantly reduced system weight while maintaining mechanical reliability. A passive compliant gripper, counterbalance mechanism, onboard storage net, and landing gear were integrated to evaluate the arm in a practical harvesting scenario using cherries as the test object. The final integrated system weighs 0.351 kg during operation, remaining approximately 16% below the experimentally determined UAV payload limit of 0.4185 kg. Proof-of-concept flight demonstrations confirmed successful aerial grasping of cherries, validating the feasibility of the proposed lightweight manipulation approach for agricultural applications.