Introduction:
Many people only see the feathers and the movement, but for me as a maker, the most fascinating part is the part that we don't normally see - the skeleton itself and the mechanism that holds it all together.
Since I'm taking the wings to KEFUR in WIP (Work in Progress) status, let's take a look at what version 1 is actually made of.
🔩 1. Aluminum joint mechanism
The basis of everything is aluminum. No 3D printed plastics that would break under load, but honest metal arms connected with bolts and nuts. I chose aluminum because it is:
• Easy (I don't want to pass out from fatigue after an hour at the con).
• Strong (will support the weight of the entire lip structure).
• Easily workable in domestic conditions.
🚲 2. Bowden cables (Cyclomechanics in action)
How do I transfer the movement from the straps to the wings? You can find the answer at your nearest bike repair shop. I use classic Bowden cables. When I pull the control, the cable contracts and the mechanism expands. It's pure mechanical physics without the need for motors or batteries.
🧵 3. Denim sleeves and blacksmith thread
In order to have something to attach the pens themselves to, I had to sew sturdy “sleeves” for the aluminum frame. I chose light denim because it is extremely resistant to tearing. It is all hand-sewn with thick blacksmith thread. No machine, pure handwork stitch by stitch.
🪶 4. Feathers: Contrast of blue and white
For version 1, I opted for a graphically clean contrast:
• Primary feathers: Dark blue foam (EVA foam), precisely cut and numbered from R1 to R9.
• Secondary and Tertiary feathers: Pure white, which I'm currently working on with stencils.
What awaits me next?
The mechanics are now ready for the con stress test. I still need to secure the sharp edges of the aluminum (carpet tape will do the trick!), sew the Velcro counterparts to the bodysuit, and I can start attaching the first pens.
Follow me, in the next blog I will show how the wings survived their first con premiere!
— Lumirainyx, Gemini