Characterization of compact precision couplings for passive alignment in origami-based deployable space systems

Origami-based design benefits deployable space systems by enabling both compact stowage and large-area deployment, leading to increased performance and instrument resolution. However, increased precision in panel positioning is required for certain applications, including deployable optical systems. This work presents five compact Maxwell-type kinematic coupling designs for origami-based deployable space systems that improve passive alignment within stringent geometric constraints. Extension arms are introduced to increase groove spacing. Tradeoffs are identified, assessing the effects of groove orientation, spacing, and clamping force on repeatability. The best-performing design achieved sub-2 µm positional and sub-15 arcsecond (0.0042°) angular repeatability across all axes. This represents a multiple order-of-magnitude improvement over existing couplings for origami-based systems, establishing a new state-of-the-art for this domain. Groove orientation and spacing significantly affected repeatability, though extension arm geometry and material may influence coupling stiffness and angular repeatability. Clamping force had no significant effect. This paper makes three contributions: (1) development of compact coupling architectures for origami systems; (2) experimental quantification of repeatability in six degrees of freedom; and (3) identification of geometric design parameters that dominate coupling performance.