A Provenance-Audited Load Transfer and Structural Screening Workflow for a Hummingbird-Inspired Flapping Wing Mechanism

A provenance-audited load transfer and structural screening workflow is presented for a 28 g, 25 Hz hummingbird-inspired mechanism. A saved unsteady vortex lattice case is linked to Autodesk Inventor load curves and motion load-informed static studies. The Curve_Example_90 record describes a 90 mm semi-span wing under prescribed 25 Hz kinematics. Its cycle 3–4 phasewise vector RMS difference is 0.0466 N (53.1% of the final-cycle vector RMS), so the latest complete cycle supports deterministic export rather than aerodynamic convergence. Positive-span panel forces were summed, transformed into Inventor axes, and interpolated without amplitude scaling; the maximum exported resultant is 0.17599 N. A normalized 16-position index map is declared between saved aerodynamic time and Inventor report time, but the retained files do not prove an encoder-defined absolute stroke-phase origin. All 96 intended component–phase records are identity-qualified. The aluminium 6061 maxima are 14.82 MPa for the force bar, 6.98 MPa for the wing-link bar, and 0.0134 MPa for the motion bar. Corrected PLA properties are serialized in the latest force bar link and wing bar reports, while the rotation pin report retains obsolete material metadata. Solution timestamps, displacements, and safety factors further show that the polymer export mixes refreshed and cached states, so polymer capacity is withheld. The common three-pass adaptive mesh setting improves within-study refinement but is not an independent mesh convergence study. The study is an empirical-to-numerical hypothesis check and design fault screen, not an aerodynamic or structural optimisation campaign; mesh-converged capacity, synchronized force/deformation validation, and print-calibrated material claims remain outside its evidence boundary.