The rapidly increasing utilization of small satellites has led to a growing demand for improved solar array technologies. Traditional solar arrays are limited by their mass and volume constraints, and thus are struggling to meet the increased demands. This feasibility study explores the potential of roll-out solar arrays as a solution to enhance the power generation capabilities of small satellites. These innovative systems are characterised by their unfurling method of deployment, and have demonstrated improved performance compared to traditional solar arrays. By analysing the feasibility of designing a roll-out solar array for small satellites, it is hoped that the operational capabilities of small satellites can be enhanced.

A comprehensive literature study revealed a significant performance gap in high power-to-mass ratios for satellites with a power range of 300 − 1000 W , leading to the development of a roll-out solar array design specifically for this power range. The study combined an analytical model with the non- dominated sorting genetic algorithm (NSGA-II), an efficient multi-objective optimisation algorithm, to generate a set of optimal designs by maximising the power-to-mass ratio and stowed power density, with the latter parameter being another key performance indicator for roll-out solar arrays. The analytical model incorporated the core design elements of a roll-out solar array like deployment mode, deployment mechanism, solar cell type, and stiffening method. A multitude of constraints ensured the feasibility of the designs, while several verification and validation tests were conducted to confirm the accuracy of the analytical model.

The optimisation results revealed that a variety of design combinations exist that could outperform the state of the art solar array capabilities. Optimal designs demonstrated power-to-mass ratios exceeding 145 W /kg and stowed power densities over 55 kW /m3. These designs would deliver over double the power-to-mass ratio of traditional solar arrays in the 300 − 1000 W range, while remaining comparable to the 120 − 140 W /kg state of the art performance of arrays outside of this range. Furthermore, optimal designs offer up to 40% increases in stowed power density compared to the 40 kW /m3 state of the art benchmark. Despite the promising gains, the study reveals some key limitations to roll-out solar arrays. These are the increased development costs, the higher risks, and their bulky geometry being potentially inefficient for smallsats. Ultimately, the study provides for a strong foundation for the development of a roll-out solar array. The results confirm the potential of such a system, and future research is recommended to solidify the feasibility of this innovative technology.