In recent times, there has been a growing interest in spending extended amounts of time in outer space. To enable these endeavors, living and storage spaces will have to be much larger than current technologies can transport and set up in space. An interesting solution to this problem is the usage of a deployable structure that occupies a small volume in a launch vehicle but can be deployed to larger volumes in space.

This thesis explores the concept of origami–known for its compactness, ease of deployment, scalability, and structural integrity– to create a deployable structure by developing a technology demonstrator that fits in a 12U CubeSat. Engineering origami has been used across many fields such as medicine, architecture, and most recently, space. For space applications like instrument booms and antennas, it is used to save space in the satellite housing them. The current work aims to translate this space-saving strategy to a larger application by creating an origami-inspired small-scale deployable structure that, if successful, can be scaled up for different purposes.

Based off requirements set by the mission, research objective, and constraints, four design
concepts are proposed. For the chosen concept, suitable materials and a compatible manufacturing technique are chosen. The structure is then modelled and prototyped to test its feasibility and determine the configuration that provides maximum compactness and inner volume–two criteria that are critical for sizeable modules to be transported in rockets with limited space. Finally, the structural performance of the deployable unit during folding and deployment is studied.

This thesis work lays the foundation for developing Kresling origami-based deployable structures with insights into optimal configurations, material and manufacturing options, and the development of a parametric model to rapidly check the geometric feasibility of a proposed structure.

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.