Biomimicry takes flight in 3D printed BionicBee

Humans have long been interested in biomimicry as an approach to designing more efficient materials and systems. While some early attempts were not so successful—such as Da Vinci’s bird-inspired human flying maching—others have been groundbreaking. Such is the case with the BionicBee, a miniature flying object developed by automation specialist Festo. 

The BionicBee is a micro aircraft notable for its autonomous nature as well as its ability to navigate tight, complex spaces and to be operated as part of a swarm. With a wingspan of 240 millimeters and a weight of just 34 grams, the flying object is currently the smallest flying object in Festo’s Bionic Learning Network, a feat which was not without its challenges, but that was ultimately enabled thanks to EOS’ Fine Detail Resolution (FDR) technology.

Conceptualizing the BionicBee

“The BionicBee was born from Festo’s Bionic Learning Network, which explores nature-inspired engineering solutions to address real-world challenges,” explained Mattias Speckle. “In this case, the idea was to rethink autonomous flight by studying the extraordinary agility and efficiency of a bee in nature.”

Bees themselves have a unique way of flying, which enables them to move rapidly between flowers to collect nectar and pollen. Their movement is characterized by short, rapid wing strokes and a rotation of the wing. In combination with strong flight muscles, this approach means that bees can fly efficiently with relatively small wings compared to their body size.

“Instead of developing a conventional drone, the team set out to design a micro-aircraft that mimics a bee’s lightweight, highly maneuverable structure—with the aim of enabling swarm behaviors for applications in complex environments,” Mattias continued. “The project was also a way to push the limits of design and manufacturing to demonstrate what’s possible when biological principles meet advanced engineering.”

Finding the right solution

When designing the autonomous micro flying object, the Festo team had to find the right balance between achieving a small, lightweight structure while maintaining durability and functionality. The team also had to figure out a structure that could remain compact while still housing several components, including a brushless motor, three servomotors, a gearbox, battery and several circuit boards. 

Unsurprisingly, additive manufacturing quickly became a clear solution for Festo in the BionicBee’s development. “Very early in the development process it became clear that additive manufacturing would be essential,” Mattias added. “The BionicBee’s design requirements—an ultra-light yet robust frame with extremely fine, intricate geometries—simply couldn’t be met using conventional manufacturing methods. The need to house multiple electronic components in an incredibly small, lightweight body demanded an optimized lattice structure that would be nearly impossible to produce without AM.” 

Early on, however, the team struggled to achieve the right metrics in terms of strength, flexibility and resolution using conventional selective laser sintering (SLS). “Conventional SLS simply couldn’t deliver the ultra-thin, high-resolution structures needed to balance minimal weight with sufficient strength. These limitations made it clear that a different solution was necessary,” they said.

That solution came in the form of EOS’ FORMIGA P 110 FDR machine, based on the company’s Fine Detail Resolution technology. The powder-based polymer 3D printer is equipped with a CO laser that boasts an ultra-fine beam (half the diameter of standard SLS), making it possible to print strong nylon components with a dimensional accuracy of +/- 40 µm and a minimum wall thickness of 0.22 mm.

Bringing the swarm to life

By working closely with Austrian manufacturing partner 1zu1 and leveraging EOS’ FDR solution, Festo was finally able to successfully print the frame for the BionicBee, achieving the necessary standards on all fronts in terms of strength, capacity and minimal weight. 

The flying object frame in question was 3D printed from PA 1101, a castor-oil derived nylon grade known for its high impact resistance and thermal stability. The Festo Bionic team also optimized the structure using algorithm-driven modeling, which made it possible to reduce the part weight by a stunning 85% from 20 to just 3 grams without compromising performance. 

On top of that, the use of additive manufacturing in the development of the project allowed Festo’s team to stay on top of deadlines and test various versions of the flying object frame without drawing out lead times. “3D printing enabled fast iteration cycles, which was critical given the tight project timeline,” said Mattias. “From the outset, Festo saw AM not just as an option but as an enabler of the entire concept.”

In the end, Festo has successfully created a bee-inspired micro flying object with the ability to beat its wings at a frequency of 15 to 20 hertz and has four degrees of flapping freedom. This gives the flying object the ability to maneuver tight spaces and the agility to fly in a swarm—something which Festo demonstrated with a synchronized swarm of 20 units.

“BionicBee has become a showcase for what’s possible with high-resolution AM in lightweight design,” Mattias added. “The success of this project opens up many other opportunities—from advanced aerial robotics and micro-flying objects to any application where weight reduction, intricate structures and rapid iteration are critical. In particular, the demonstrated ability to reduce frame weight by 85 % while maintaining structural integrity suggests a huge potential for other aerospace, automotive and even medical applications that demand precise, durable, ultra-light components. 

“The collaboration also showed how AM can shorten development timelines, making it attractive for innovation-driven industries looking to move quickly from concept to functional prototype and production.”