Instructables
A skeleton set of wings made from balsa wood and an old frame backpack, suitable for angels, bats, demons, birds (but not so much for butterflies or other insects). They open and close as you raise your arms, and flap forward and back when you do. Decorate them with leather, feathers, streamers, gold paint, whatever strikes your fancy. Mine ended up with a 9 foot span when open fully.



I wanted a very lightweight wing that would not tire me if I wore it all night. I chose balsa wood over aluminum tubing because it's easier to work with given the tools I have available. The basic structure could be made out of almost any stiff material, however. (My prototypes were made from popsicle sticks and foam core.) Each wing is a simple set of linkages arranged to expand and rise when opened.
 
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Step 1: Tools & Materials

Picture of Tools & Materials
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Except for the backpack, which you may be able to find in a thrift store or Army Surplus if you don't already have one in your garage, all the materials needed can be found in a hardware store and/or craft store.

(A) 1 aluminum frame backpack
(B) 3 pc of 36" x 4" x 1/4" balsa wood
(C) 1 pc (60" length) of 1/4" wood dowel
(D) about a foot of "hanger strap" - a thin strip of metal with holes in it, mine came coiled up in a packet (found in the plumbing section)
(E) 4 nut/bolt sets, bolts of a diameter to fit through the holes in the hanger strap, and as short as you can find (they are used to fasten the hanger strap tight around the wing supports)
(F) 8 shaft collars with inside diameter 1/4"
(G) 6 pc 3/4" machine screws that fit the threadings in the dowel collars (F)
(H) 2 pc 1/2" machine screws that fit the threadings in the dowel collars (F)
(J) 4 pc 1/2" binding posts for the balsa/balsa hinges
(K) 2 pc 3/8" binding posts for the balsa/hanger strap hinges
(L) 10 pc 1/4" long nylon spacers, that the binding post (J) fit through
(M) 6 pc 1/4" long nylon spacers that the machine screws (G) will fit through (and turn; these will be some of the wing hinges)
(N) 4 nylon washers, 1/16" thick, that fit around the binding posts (J)
(P) a number of small nylon washers, 1/16" and 1/32" thick, that fit around the machine screws (G) 1
(R) 2 nylon flanges (I am not entirely sure this is the right term) to fit into the aluminum tubing of the backpack
(S) scrap leather
(T) couple inches of velcro

1 these washers are to pad the hinges created by the collars & the machine screws, so the thicknesses are determined by the actual dimensions of the hinge assemblies. I used, I think, 8 of the thicker ones and 6 of the thinner ones, but I suggest buying these later once you're ready to assemble the hinges and can take the wing parts into the hardware store and measure, or just get a bunch and use them as needed (they cost me something like 6 cents each).

Tools:
  • x-acto knife
  • Dremel or power drill with a cutting wheel attachment & a 1/4" metal drill bit
  • tin snips (you can use the cutting wheel if you don't have tin snips)
  • 2 pair needle nose pliers
  • wood glue
  • hot glue gun
  • screw drivers appropriate for your bolts and screws
  • sandpaper or fine file (I use fingernail files)
  • sewing machine or needle & thread
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i really like the idea of these wings. Do you ever commission yourself to build them for others?

rachel (author)  patrick.hill.37602 months ago

I haven't made a set for anyone else but I am open to the idea - PM me and let's talk!

Hey! Im also wondering if you do commissions but I don't know how to message you :/ please email me at happythorn07@hotmail.com
Thanks so muh!

Okay I have ben wanting to start this as a project for awhile now but the only thing that I don't get is how do you put shirts/jackets on over the wings or harness? I want to do this for my Gabriel cosplay and he wears a jacket so if I bought or made one would I have to cut it up in the back and ruien it?

http://whatishcc.com/tutorials/wing-harness/ here is a good idea without messing up the back to much. wish i had this sooner xD

im was thinking the exact same thing for an attack on titan cosplay im doing with wings. im not sure how else you would get them on so i just bought a cheeper lower quality jacket and tore out the back. hope this helps

talei.mikulas3 months ago

How did you attach feathers to it?

i attach feathers by covering it in chicken wire and hot glueing the fetahers to it

Does anyone have any tips on making these more like Max's from Maximum Ride? I very much want to be her for Halloween this year. Please let me know, I want them to be as bird-like as possible. Thanks.

I love maximum ride and the best i could say would make the wing span bigger and attach feathers that look those similar to an owl. I attach my feathers by covering it in chicken wire and hot gluing the feathers to the wire. sorry if this is really late but i hope it helped.

Do you, by chance, still have a pattern for the wing bones I could print and cut out?

Hi! It looks marvelous, and I have to admire the amount of work you put in so the rest of us don't. ;) I know I couldn't have figured all of this out on my own.

One thing, is there a way they could open and close without the arm bands?

Hello author, :)

It looks really awesome, congratulations !

would you have any idea on how to make articulated wings that sit on the hips, not back and shoulders and open flat (not standing) ?
Like in the two images down here (1st : closed wings, not that they are slightly curved, 2nd : opened wings, the behind of the wing facing down, not facing front like normal wings).

They don't have to be huge, mind you. :)

The way they stand make them harder to make :( I'm having issues, but since you can do such awesome things, maybe you know how to help me ?

Odin Sphere - Gwendolyn2.jpgOdin_Sphere__Valkyri_Gwendolyn_by_blackmage9.jpg
rachel (author)  IchigoCosplay1 month ago

Thank you for the kind words! Those wings do look harder to manage. If I were making them I would start with a small prototype model, maybe popsicle sticks and toothpicks, or heavy paper and staples, and just mess around until I got something that worked. Then I would figure out how to scale it up to (I assume) person-sized. They will clearly need a sturdy corset-like garment to support the wing bases, and that is also a possible starting point for figuring out the wing structure. I guess you will want to come up with a different opening/closing mechanism than attaching to the wearer's elbows. All in all, an interesting problem! I hope you will post an Instructable about the solution you come up with!

koroko11 month ago

Please post the exact measurements for the materials you used and where you bought it. I tried looking for them and it took me forever and went to three different stores looking for the materials and I havent found some of it. It would help thanks!

rachel (author)  koroko11 month ago

Unfortunately I can't do this - I made these wings about 5 years ago and I don't remember that level of detail any more. Improvise with what you've got - not everything I used was optimal, particularly the balsa wood which was too soft to keep the hinges and I would recommend a different material for the bones.

koroko11 month ago

Please post the exact measurements for the materials you used and where you bought it. I tried looking for them and it took me forever and went to three different stores looking for the materials and I havent found some of it. It would help thanks!

sarah.gawle2 months ago

I don't have the tools NOR the materials to make it how you did (though mine would have been much prettier and hardier if I did!).

My materials were:

-broken umbrella

-caradboard

-screws

-washers (decorations)

-knuts

-white fabric

-duct tape

-fishing wire (though fishing line is as good. Twine is not, because it succumbs to pressure more easily and snaps)

I took apart the umbrella and the "arms" already bend the way I wanted for wings. I threaded the fishing wire through the hole at the back of the farthest-reaching "digit" of each umbrella "arm" so that when I pulled it, it would extend the entire arm like a wing. Then I attached them to a cardboard backing I made with duct tape, made holes in the cardboard backing, and criss-crossed the wires through so I could pull on the strings while wearing it. I added old belts as straps, though you can make duct tape straps. I cut out the white fabric and sewed it around the umbrella arms. The washers I used to decorate to make the holes around the cardboard look a little better, and I also covered it in a wood varnish so as to maybe fool people into thinking it's made of good wood.

It doesn't work.

But all in all I made some working wings for less than $10. Though if people are feeling ambitious and want well-working wings, I would hope they use your tutorial!

rachel (author)  sarah.gawle2 months ago

This sounds like a super interesting technique. Can you post a picture? I'd love to see your wings.

Fortunately, the cardboard for this pair (the digits I saved from the umbrella allowed me to make 3, but this is the best one) came from a box of Steampunk accessories I had bought online, so it had a cool logo on it.
I don't know if it's visible in the pictures, but I also tied the ends of the wire around curtain rings so that they wouldn't poke or get caught around stuff. That way my finger slips into the loop rather than reaching for the end of a sharp wire.
I apologize for the random stuff in the picture, like me leg, my scarf and my shoe!
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rachel (author)  sarah.gawle1 month ago

Thanks for the pics, that's a great low-cost alternative.

ewickerham3 years ago
This is a wonderful idea and i am addicted to the idea of having wings, one year for halloween i had made those lil fairy wings out of wire hanger and stockings but i rlly want feathered wings. so i look at all these websites and find how to make wings out of cardboard..... well those wings are great but they dont move >.> so after a while of searching for articulated wings i found this, i love this idea and think it would be amaizing but i was wondering, how do u make the skin or feathered part???... and do i have to buy a really good quality backpack? cuz it cant get too pricey.... i LOVE this idea.. im trying to think how to cover the ugly frame... i mean it is beatiful work its just not what u want to see when u are supposed to be looking at a pair of angel or elsewise wings..... BUT I LOVE THIS!!!
rachel (author)  ewickerham3 years ago
A little while ago I saw where someone had made similar wings like this, but instead of using a backpack, they had made slots in a corset, to slide the wing supports into. If I were to make these again, I would use that method, it is much sleeker and made the wings really look like they were attached. Unfortunately I didn't save the link to it :(

Is this one similar?? I found it online and was thinking of changing it to work with your amazing wings. Problem is, when you search "corset for sale" you figure out what they are most often used for these days...

http://whatishcc.com/tutorials/wing-harness/

These look fantastically great! Do the wings open up if you put your arms up and forward too??

I would appreciate it if someone could estimate a cost for these. while estimating cost for feathers, without surface area calculation to work with, I came up with at least 50 bucks. :/

I spend about 50 for feathers. I'm sure if you do some hunting you may be able to find some place that will sell you them for cheaper when what i paid. I used under a 1/2 lb.

and could you maybe post a picture??

How did you adhere the feathers to the frame??

I made it and it works great for my Hawkgirl cosplay. I don't have to many pictures up but if you want to check it out in a week or so I should have more up on my facebook. Your instructable was great and easy to follow. I used a heavy gauge wire and a corset with channels to keep the wings on instead of a back pack. Also if you want to put feathers on it go slow! Try the feathers in a few different places with tape and make sure it still opens and closes. I made that mistake and it wasn't fun. I was able to cover both wings with just about 1/2 lb of feathers. Thanks so much!

https://www.facebook.com/PICosplays

My facebook if you want to check out the picture(s)

rachel (author)  jessica.gladstone.984 months ago

That looks great! I'd love to see a pic with the feathers, please do comment here when you post that!

Here4Cosplay5 months ago

Is there a possible way to change the way the wings open without ruining how they do so? I would like to make it so that they open when the arms are thrust downwards instead of upwards to apply a more comfortable pose for photos.

I was wondering how this would work with real feathers or worbla-made feathers without the feathers bunching up? Thanks!

MykelDavid6 months ago

What are the exact measurements for the bones... I am making these and have all my supplies and the feathers and just need the dimensions so i can start the project.. THanks

Do you by chance have the bone patterns still ???? you realy do not go in depth on that unfortunately. things like size of each bone compaired to wing span would be helpful

tgryffyn6 months ago

Your Instructables here was featured on Adafruit's blog. Good job!

(originally attributed to a Tumblr where someone just hotlinked to your photos but they corrected it)

http://www.adafruit.com/blog/2014/05/27/building-articulated-wings-framework/

tgryffyn8 months ago

Just a h/t to you for some inspiration in my early planning stages for some possible wings for my girlfriend. I wanted to take a step back and do some prototyping first and thought I'd document what I had done. My first Instructable!

Your instructions and parts list will come in very handy later when we go to make the real thing. I thought mine might help people who are intimidated to dive into a full scale thing and/or might be interested in doing something similar on a smaller scale (pets, toys, etc)

Thanks!

http://www.instructables.com/id/Mini-Model-Articulated-Wings/

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Partybot1 year ago
I used your design as a basis for my dragon costume. Thanks!
http://www.instructables.com/id/Dragon-Costume/
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rachel (author)  Partybot9 months ago

Wow! Amazing work.

fbollen made it!9 months ago

Thank you so much! A great instruction! With some fabric it became my carnival costume and I won as the second in the costume show of my school! :)

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