1. Introduction
Birds have served as a source of inspiration for aircraft design for over a century [
1]. They are capable of seamlessly morphing their wings and manipulating their tails to achieve precise and controlled flight. Hawks, in particular, can sustain efficient gliding flight while rapidly transitioning to aggressive maneuvers such as dives, making them among the most effective flyers in nature. Red-tailed hawks (RTHs) specifically possess long, broad wings that enable extended soaring followed by tight, agile maneuvers to capture prey [
2]. Recent studies of RTH flight have examined their adaptability in turbulent environments, showing that they pitch their wings and tails to mitigate the effects of gusts [
3]. Birds achieve such seamless flight through specialized biological structures and mechanisms. Understanding the mechanisms by which they tuck their wings has been critical to the development of morphing drones, as these natural strategies directly inform engineered solutions [
4].
It is difficult to fully capture the agility, aerodynamic efficiency, dimensions, and material properties of a bird in a manufactured drone. A wide section of biomimetic research focused on developing a single avian-inspired morphing component for a traditional airplane. Ajanic et al. [
5] developed a bionic wing modeled after a jackdaw able to flap, pitch, and fold. Murayama et al. [
6] presented a tail capable of tail pitch, tilt, and rudder motion. Zhang et al. [
7] analyzed a shape-morphing avian-inspired wing. Various studies sought to develop a morphing unmanned aerial vehicle (UAV) inspired by different avian species. Ajanic et al. [
8] demonstrated the effects of asymmetric wing tucking, compared to outer wing pitching, as a means of reducing the turning radius of LisEagle, a feathered morphing drone inspired by eagle flight. Chang et al. [
9] incorporated real pigeon feathers into the design of PigeonBot II and successfully demonstrated flight without a vertical stabilizer or rudder. Phan and Floreano [
10] incorporated an entirely artificial, feathered-wing design comprising three segmented wing components in their Raptor drone, enabling wing and tail shape morphing, tail elevator deflection, roll, and lateral deflection. Other artificially feathered bioinspired drones, including MataGull [
11] and CGull [
12], both inspired by seagulls, also featured tail and wing morphing.
One of the greatest challenges in designing drones with morphing and feathered wings and tails is the increased potential of fluttering when joints are introduced in the wing structure. Reinforcing the morphing structures can easily introduce weight penalties. To address these challenges, this paper presents a UAV inspired by the flight characteristics of the RTH. The drone, named SMART Hawk (Shape-Morphing Artificial Red-Tailed Hawk), is designed to incorporate five degrees of freedom (DOFs): two in the wings to enable asymmetric wing tucking, and three in the tail to allow pitch, roll, and feather expansion. A feathered wing and tail configuration is implemented to more closely replicate the morphology of a real bird. The wing and tail systems, including the morphing mechanisms and the feathers, were designed to be lightweight yet possess high specific stiffness to avoid flutter under aerodynamic loads. The rest of the paper is organized as follows:
Section 2 details the preliminary computational model developed in various software packages.
Section 3 describes all components and subsystems of SMART Hawk.
Section 4 presents the manufacturing and testing steps that were completed. A summary and conclusion are given in
Section 5.
4. Manufacturing and Testing
The process of manufacturing the wing feathers began with a high-density foam mold designed in SOLIDWORKS, then exported to Autodesk Fusion for toolpath generation, and machined on a CNC router, after which the mold was sanded and coated with Duratec to achieve a smooth surface finish. Once the primary mold was fully prepared, a wet layup process was followed to apply seven plies of fiberglass and high-temperature epoxy to produce a secondary mold capable of withstanding elevated temperatures during subsequent prepreg fabrication. Prepreg carbon fiber was selected over traditional wet layup carbon fiber due to its controlled resin content and optimal fiber-to-resin ratio. The feather geometry was cut from carbon fiber prepreg using 3D-printed stencils laid onto the fiberglass mold to form the cambered feathers, as shown in
Figure 10a,b. Aluminum rods acted as the shaft of each feather and were selected for their favorable stiffness-to-weight ratio and ease of bending. Each feather consisted of two plies of carbon fiber with a reinforcement strip laid on top of the sandwiched rod.
The wing cover molds were manufactured following a similar process. The wing cover molds were 3D-printed due to time efficiency and their complex geometry, then sanded and coated with Duratec (
Figure 11a). The same wet layup process was used for manufacturing, with five plies of fiberglass to create a secondary mold (
Figure 11b). The wing covers were made with three plies of plain weave carbon fiber prepreg placed inside the fiberglass mold to achieve the desired shape (
Figure 11c). Aircraft fabric was used to bridge gaps and create a continuous aerodynamic surface between the wing covers and inner wing, with additional fabric applied along the underside of the trailing edge and reinforced by chordwise carbon fiber rods to provide structural support and reduce vortex formation identified in prior modeling.
The inner wing structure was built from balsa and basswood ribs and stringers, assembled around the humerus, which was positioned first. The stringer components were soaked in warm water and dried at a preset angle to achieve a 5° dihedral. The framework was then covered with UltraCote to form the airfoil shape.
The fuselage was constructed from foamboard due to its low weight and rapid manufacturability, allowing the fuselage airfoil profile to be cut and shaped efficiently using CAD-generated templates. The airfoil cross-section for the wing insertion was cut using precision blades to achieve the desired airfoil contour. To reinforce the fuselage structure and provide adequate load transfer between the fuselage and wing assembly, wooden dowel attachments were inserted perpendicular to the internal walls. 3D-printed brackets were glued to the fuselage walls, acting as C-clamps, allowing for quick wing removal and accurate mounting.
The tail feathers were laser cut from 2 mm balsa wood to ensure dimensional accuracy and repeatability, with balsa selected for its low density and adequate stiffness for aerodynamic loading. A single-ply carbon fiber patch was bonded to the balsa using epoxy resin through a wet layup process to attach a 2 mm carbon fiber rod to each feather, as shown in
Figure 12a. Epoxy resin was selected for this interface due to its superior bonding strength compared to cyanoacrylate adhesives and for the added stiffness that resulted from the absorption of resin in the balsa feather. The fixed horizontal feather had two carbon fiber rods bonded at each end to provide additional structural support to the balsa wood. A precision slit was cut into the horizontal fixed feather to allow a vertical stabilizer to sit on two PLA brackets. This vertical stabilizer is added for stability during preliminary flight tests. To further increase stiffness, two carbon fiber rods were bonded to the vertical stabilizer (one from each side) along with the two PLA support brackets, as shown in
Figure 12b.
Actuation tests on wing and tail morphing were conducted, as seen in
Figure 13. All servomotors successfully actuated the wing and tail mechanisms from expanded to fully tucked positions. The tests were also performed when the models were placed in an airflow generated by a wind generator with a wing speed close to the maximum drone’s air speed. This qualitative low-speed airflow exposure test was conducted to observe feather and wing vibration behavior under forced airflow conditions. Actuations were consistent in all tests conducted which exceeded 50 times for each morphing action. The preliminary bench-top airflow excitation test did not show any visually observable large-amplitude oscillations in the feathers, the outer wing structure, or the tail structure, throughout the one-minute duration of the test. A top view of SMART Hawk prototype assembly can be seen in
Figure 14. The weight of the initial SMART Hawk prototype is 1.67 kg. Weights of individual components are as follows: fuselage: 65 g, tail structure: 130 g, single wing with servos: 870 g, single wing primary and secondary feathers: 6 and 8 g, respectively, and a single tail feather: 4.2–7.2 g. The CG is positioned at 23% of the inner wing chord measured from the leading edge, a location identified through multiple morphing-tail flight tests as optimal for providing sufficient tail pitch authority.
Given SMART Hawk’s unique control surfaces, an iterative approach was used to characterize the control signals and achieve flight stability. As shown in
Figure 15a, a basic aircraft model with traditional tail and wings, having the same tail and wing surface area, was mounted on the SMART Hawk fuselage. After achieving proficient control with this conventional model, the SMART Hawk tail replaced the traditional tail (
Figure 15b), followed by the SMART Hawk wings with a traditional tail (
Figure 15c), culminating in the final iteration with both morphing wings and tail (
Figure 15d).
The intended flight plan consists of a one-minute flight sequence in which the SMART Hawk takes off through hand launch, ascends, and achieves stable flight before executing asymmetric left wing tucking for a full 360-degree turn, followed by asymmetric right wing tucking for another 360-degree turn. The drone then performs symmetric wing tucking to initiate a dive, levels out, and completes a controlled landing. All flight tests were conducted at the Apollo XI model aircraft field, Lake Balboa, CA. Weather conditions during all flight tests were as follows: temperature high ~76 °F, low ~56 °F; wind speed 4–10 mph, with occasional mild gusts up to 12 mph; precipitation 0.0 inch; and humidity 45–50%. The traditional drone of the same approximate size and avionic system was initially tested (
Figure 16a). A more complex flight plan was executed with this drone with the help of a licensed and experienced RC plane pilot. The morphing tail was then added to the drone, replacing the traditional tail. Flight testing of this drone (
Figure 16b) demonstrated the ability to steer the drone using only tail morphing, creating banking angles and turns without ailerons, and landing safely during multiple flight tests, each exceeding two minutes of flight time. Each of the initial two flight tests of SMART Hawk, shown in
Figure 16c, achieved a total flight time of 10 s. During the first flight test, the pilot reported difficulty maintaining roll stability due to minor asymmetry in the wings that caused the aircraft to tilt during takeoff. In the second flight test, SMART Hawk successfully flew along a straight path. However, the pilot was unable to carry out a banked turn which led to the aircraft rapidly losing altitude. This result suggests that additional pilot training and familiarization is needed to control SMART Hawk’s unconventional control surfaces.
Video S1 in the Supplementary Materials shows some of the performed flights tests.