A laser-microfabricated electrohydrodynamic thruster for centimeter-scale aerial robots

To date, insect scale robots capable of controlled flight have used flapping-wings for generating lift, but this requires a complex and failure-prone mechanism. A simpler alternative is electrohydrodynamic (EHD) thrust, which requires no moving mechanical parts. In EHD, corona discharge generates a flow of ions in an electric field between two electrodes; the high-velocity ions transfer their kinetic energy to neutral air molecules through collisions, accelerating the gas and creating thrust. We introduce a fabrication process for EHD thruster based on 355 nm laser micromachining, which potentially allows for greater materials selection, such as fiber-based composites, than is possible with semiconductor-based lithographic processing. Our four-thruster device measures 1.8 x 2.5 cm and is composed of steel emitters and a lightweight carbon fiber mesh. We measured the electrical current and thrust of each thruster of our four-thruster design, showing agreement with the Townsend relation. The peak thrust of our device, at 5.2 kV, was measured to be 3.03 times its 37 mg (363.0 mu N) mass using a precision balance. In free flight, we demonstrated liftoff at 4.6 kV.