Origami folding pattern development for gossamer structures

Gossamer structures for satellites are large, thin deployable structures that are attractive for space applications because they can be stowed compactly for transportation and deployed to have large functional surface areas. Reflectarray antennas, in particular, are candidates for gossamer structures because they can be realized on thin membranes. However, the efficiency of reflectarray antennas decreases with any deviations from a flat plane, including those induced by plastically deformed creases. Rolling membranes can prevent some plastic deformation , but requires relative slipping between layers that are rolled together. In this work, we describe, analyze, and demonstrate two rolled configurations for deployable gossamer structures based on a combination of rolled and folded membranes and surrogate folds that allow for sliding between layers. Cuts and Step Hinges are used as surrogate folds. Step Hinges connect membranes while limiting slipping motion in a single direction and reducing wrinkling in the structure. The combination of folding, rolling, and sliding connections reduces plastic deformation while providing a highly efficient packing of the stowed form. • Gossamer structures with minimal plastic deformation are proposed for the underlying structure of reflectarray antennas. • For two configurations, we model the between-layer slipping required to allow a gossamer structure to fold and roll compactly. • We develop the Step Hinge, a surrogate fold that allows for slipping in one direction and reduces the effects of plastic deformation. • Our two rolled configurations incorporate surrogate folds to reduce plastic deformation.