Flying vehicle that is propelled by flapping wings also known as flapping-wing air vehicles (FWAV)/Ornithopters has been a subject of exploration due of its possible use towards unmanned air vehicles (UAV), micro air vehicles (MAVs). Birds and insects fly with unprecedented agility in flight. These FWAVs seek to mimic the motions of such naturally found species. They can find their use in military surveillance or for forestry and wildlife survey. Ornithopters are vehicles that generate the necessary thrust and lift by flapping motion. This exploration work contains a detailed description of the mechanical and the electrical systems used in the FWAV. This paper also focuses on the production process involved in the making of FWAV. This paper also gives an insight about the initial control experiments that were performed. Instead of focusing on problems of small MAV which revolves around miniaturization of the mechanism and electrical energy storage. Our work concerns itself more with the topic of robot locomotion. Thus, it will give details about how one can achieve better stability and control on the flight of an Ornithopter. The developed FWAV has a wingspan of 1.17 m, designed for a kerb weight of 1000 grams. The prototype has been designed specifically for the use of exploration. The designing make extra efforts to enhance payload size, control stabilization, wing efficiency and crash survivability. © Springer Nature Singapore Pte Ltd. 2019.