In this Post the manufacturing process of the Quadrotor used on the HyTAQ is illustrated. In case you have not seen the video of this system here is the link:  HyTAQ

Structural parts of this miniature quadrotor has been fabricated using the shape deposition manufacturing. To enhance the rigidity f the elements and also make the system more shock resistance, elements machined of aluminum sheets have been deposited in the parts. Also to eliminate the need to wires, the aluminum elements has been used to distribute power.

The first step was to machine the aluminum parts and wax block to the prepare the negative mold.

The aluminum parts are then placed in the wax block properly.

Liquid poly-urethane plastic with a shore hardness of 70D has been molded in the wax block.

The parts are then taken out and assembled.

IIT Rotocis Lab Website

[EDITOR'S NOTE:  This topic has been posted in a previous blog.  Here's the link http://diydrones.com/profiles/blogs/walking-quadrotor-aerial-vehicle]

Hi everybody,

This is one of the toys I have designed lately as a part of my graduate project.

I have submitted it to Boca Bearing innovation contest, if you liked it, please vote for it here:

http://www.bocabearings.com/innovation-contest/ContestantDetails.aspx?ProjectID=45

This is a hybrid robot capable of both aerial and terrestrial locomotion. A unique complimentary mechanical design makes it possible to use a single actuator set for both walking and flying. This is advantageous because it reduces both the total weight of the system and the control system complexity. The basic structure is similar to a quadrotor aerial vehicle, i.e. four brushless DC motors provide the required thrust for flying. The desired leg motion is derived from two separate linear movements. Horizontal motion of the leg is achieved by driving the main actuators in reverse. A second linear actuation unit, which is set into motion by shape memory alloy (SMA) wires, enables vertical movement of the leg during terrestrial locomotion.

http://youtu.be/CHxeWsvZahY