How does a FlatFlap work?

The FlatFlap is an incredibly thin and innovative actuator that brings motion to your projects in a compact form factor. To understand how it works, let's dive into the unique design and the principles behind its operation.

The Structure

The FlatFlap is designed from a flexible PCB (printed circuit board) and aluminum stiffeners. These components are carefully folded together to form the actuator.

The flexible PCB serves as the foundation of the actuator. Unlike rigid PCBs, the flexible version can bend and twist without breaking, which is essential for creating the flapping motion. The flexibility of the PCB allows the FlatFlap to move freely while still maintaining its structural integrity.

The Aluminum Stiffeners provide the necessary rigidity to hold the magnet that directs the flapping motion, ensuring that the movement is both precise and consistent.

The Magnetic System

The FlatFlap is powered by a clever magnetic system that converts electrical energy into mechanical motion. This system consists of a magnet on the back of the actuator and a planar copper coil embedded within the flexible PCB.

The FlatFlap features a 10mm N52 neodymium magnet attached to its back. This magnet plays a crucial role in the actuator's operation, interacting with the magnetic field generated by the copper coil. This coil is inside the flexible PCB, and is responsible for creating the magnetic field when an electric current is passed through it. Flapping motion is achieved by pulsing the current through the copper coil in different directions.

Depending on the direction of the current, this magnetic field interacts with the magnet on the back of the FlatFlap. By alternating the direction of the current, the magnetic field can either attract or repel the magnet, causing the flap to move. The voltage can also be varied via PWM, to control the distance of the coil from the magnet.

By rapidly pulsing the current in different directions, creating a square wave, the FlatFlap can produce a continuous flapping motion. The speed and frequency of this motion can be controlled by adjusting the rate at which the current is pulsed. In its optimal configuration. The FlatFlap can achieve a speed of up to 25Hz, creating a fast and responsive movement.

Easy Attachment and Secure Installation

Installing the FlatFlap is a breeze, thanks to its peelable adhesive back and optional screws. The adhesive provides a strong bond that keeps the actuator securely in place, while the screws offer an additional layer of security if needed. This dual installation method ensures flawless adhesion, whether you're attaching the FlatFlap to a smooth surface or something more textured.

Ultra-Thin and Compact Design

One of the standout features of the FlatFlap is its incredibly slim profile. With a flap that’s only 0.3mm thin and an actuator measuring just 2.6mm, this sleek design can integrate seamlessly into any flat surface. Its low profile ensures that it doesn't interfere with the aesthetics of your project, making it ideal for applications where space is at a limited.

The FlatFlap is perfect for a wide range of applications. It’s particularly well-suited for creating kinetic sculptures and experimenting with robotics. Its ability to add eye-catching motion to lightweight objects, such as thin 3D-printed plastic or paper origami, opens up a world of creative possibilities.