The demand for pressurized, large structures in space, such as habitats or fuel deposits, is increasing as the space industry grows. The limited payload volume of launch vehicles, combined with their highly constrained shape, presents a significant challenge for these structures. Origami-inspired deployable structures have emerged as a potential solution for this problem. This work aims to design and optimize an origami-inspired deployable structure for use as a technology demonstrator in a 12U CubeSat. The choice of pattern, deployment mechanism, and material considerations are discussed as they are relevant in the initial configuration of the structural prototype. By combining two different types of printable materials, it is possible to create a pattern that is more flexible without the use of mechanical hinges. Then two different modeling methods are analyzed in order to study their physical behavior. Once all the desired configurations are computed, an optimization process is applied in order to obtain the most suitable one under the pre-defined requirements.

Rising commercialization of the space industry has led to increasing demand for large structures in space, such as habitats and fuel tanks. However, due to the limited payload volume available, the shape of such structures is highly constrained. This calls for a structure that is flexible enough to be stowed during launch but still enough to withstand structural loads. Origami-inspired structures are an appealing design compromise as they can dynamically change their shape and volume while maintaining structural integrity. They also present the advantage of a high packaging ratio, scalability, can largely maintain their structural properties after repeated deployment, and possess flight heritage with space technology like sunshields and solar arrays. The present work aims to further the knowledge in this field by testing the viability of this concept with a deployment demonstrator fit for a 12U CubeSat mission. Two potential deployment concepts have been identified:telescopic deployment and inflation. The telescopic solution is reliable and has extensive flight heritage but adds weight and complexity to the structure. Inflation, however, is lightweight, has fewer parts, and provides a directly pressurized structure, but runs the risk of depressurization. Nevertheless, it has been used successfully to deploy origami booms and sails in space and other inflatable structures like the BEAM. Different origami patterns are selected for each of the deployment concepts. The telescopic deployment calls for the Yoshimura pattern due to its straight, non-rotational folding behaviour, and for inflation, the Kresling pattern is considered. The concepts are traded off on the basis of mission-critical criteria. After identifying a suitable origami pattern and deployment concept, a CAD model representation is created using the Rhino 3D modeling software. The model is then validated using laser-cut paper prototypes, following which it is used to identify an optimal pattern configuration that has a high usable inner volume and low packaging ratio(or folded height). Next, suitable materials and manufacturing options are traded off to identify a feasible fabrication method and materials. This is followed by a detailed description of the manufacturing process. Finally, based on the lessons learnt during the design and prototyping stages, some design guidelines are generated. Recommendations for further work are also made.

The progressive democratization of human space exploration has brought a potential demand for affordable large, pressurized structures in space such as habitats as well as fuel tanks in orbit. Unconventional space structures are a potential engineering solution because they can optimize the structural performance for the launcher's geometric limitations. Specifically, deployable origami-inspired structures allow for a compromise solution between available volume and cargo weight. Origami-inspired structures have been studied for space applications in past and recent works, but there are still gaps between the in-orbit requirements and technological challenges with the current state-of-the-art. Consequently, there is a need for small scale demonstrators for this technology that will allow to characterize and validate the deployment concept. Such a small-scale demonstrator would fit within 12U CubeSat (or equivalent small sat configurations) and would unveil possible technical challenges not considered in the modelling stage. This work explores the design of a prototype for a deployable structure with a high packaging potential and a small number of degrees of freedom. A cylindrical origami deployable structure is studied under its processes of folding and deployment. This configuration has also the advantage of a possible pressure-controlled deployment, one with special interest for habitable modules or, additionally, fuel tanks for transportation and storage. In particular, the first steps towards a complete design of the demonstrator are explored: the shape optimization, the material selection, and its structural behaviour. To design this demonstrator a parametric trade-off study of the different origami patterns is performed: looking for an optimal packaging ratio. Once the geometrically optimal configurations are obtained for each origami pattern, relevant materials are selected, and possible manufacturing challenges are discussed.