A Passive Elastic-Folding Mechanism for Stackable Airdrop Sensors

Air-dispersed sensor networks deployed from aerial robotic systems (e.g., UAVs) provide a low-cost approach to wide-area environmental monitoring. However, existing methods often rely on active actuators for mid-air shape or trajectory control, increasing both power consumption and system cost. Here, we introduce a passive elastic-folding hinge mechanism that transforms sensors from a flat, stackable form into a three-dimensional structure upon release. Hinges are fabricated by laminating commercial sheet materials with rigid printed circuit boards (PCBs) and programming fold angles through a single oven-heating step, enabling scalable production without specialized equipment. Our geometric model links laminate geometry, hinge mechanics, and resulting fold angle, providing a predictive design methodology for target configurations. Laboratory tests confirmed fold angles between 10 degrees and 100 degrees, with a standard deviation of 4 degrees and high repeatability. Field trials further demonstrated reliable data collection and LoRa transmission during dispersion, while the Horizontal Wind Model (HWM)-based trajectory simulations indicated strong potential for wide-area sensing exceeding 10 km.