Sunflake Extra Linear

Combining our proprietary Pyramid Hinge Array, with other novel mechanical and geometric solutions, we propose a disruptively compact, robust structure for Lunar Solar Power Generation The Sunflake XL array, and Ultra Compact Quad Tower (UC4T) Sunflake XL delivers a 175m ultra compact Lunar Surface Solar Array, capable of delivering 50kW of power. The solar array raises up to 10 meters off the ground (achieving a total height of 17m). Sunflake XL rotates for optimal sun tracking, while the UC4T provides a stable vertical structure. Combined together with the tower and rover-deployment system, the entire package will deliver a performance of 113 W/kg and 26 kW/m3. The system is ultra compact, lightweight, stable, and retractable. Most important, it is based on our proven pyramid hinge technology, making it a reliable and robust solution. The novel design combines the strength, compactness, and durability of the Pyramid Hinge, with linear expanding array elements, adding a new dimension of scalability to our Sunflake solutions. The novel mechanisms can also be re-configured for different deployable solutions: antennas, reflectors, or radiators. With a linear arm segment measuring only 2.6 m, the new design opens a new spectrum of opportunities for pyramid-hinge based designs. In Phase I Folditure validated the design, packing efficiency, scalability, and retractability of the mechanism, through detailed mechanical drawings, analysis, and a functional prototype. In Phase II we propose to fully develop the kinematics and structure. We plan to engineer, and build a very large-scale high fidelity kinematic prototype, while further developing, and applying the best available technologies. The design will be also proven through FEM analyses, and environmental testing. We also propose to field test the prototype deployment, with alunar rover. This project is very well aligned with our area of expertise: developing super-compact novel folding solutions. The proposed Phase II is for a novel solution for a 50 kW robust, re-tractable, compact Solar Array and Tower, adjustable to terrain variability and in height.   Utilizing Folditure’s proprietary Pyramid Hinge Array design, combined with novel linear extension mechanisms, we are developing Sunflake XL: an innovative lightweight structure that can deploy to a surface area of 175m² or more.   In conjunction we are developing a new supporting tower structure (UC4T), and a rover-based deployment system (SDS).   The Sunflake XL/UC4T is a novel foldable structure that, together with the deployment system, measures an estimated 1.875m³ when retracted. Designed to use thin and flexible solar panels, the array stows in an extremely efficient flat volume, with a maximum length of 2.6m. Together with the base structure, it reaches an estimated efficiency of 113 W/kg and 26 kW/m³.   Sunflake XL is modular, as extension array arms can be added, or removed as needed. The proposed novel mechanism will enable exponentially larger structures than are currently possible, with robust redeployment capabilities. Building a functional prototype, through CAD drawings and analyses - Folditure validated the design, packing efficiency, scalability, and retractability of the mechanism in Phase I.   Our objective in the proposed Phase II, is to further develop the new XL folding mechanism, and show its feasibility for a 50 kW array. We will also refine the design of the new UC4T tower, and rover-based transportation/deployment on the lunar surface.   Main objectives: In the proposed Phase II work, Folditure plans on building and testing a large-scale high fidelity working kinematic prototype. We will develop manufacturing details, and mechanical solutions, targeting further performance improvements. Detailed 3D models will be used to demonstrate the performance of the system. Load, thermal, and stowed vibration analysis will also be performed. Solar panel integration and relevant details will be developed. Phase II work will also be geared towards marketing the invention for Phase III and further development.   Proposed Deliverables: Large scale working prototype of the entire Sunflake XL/UC4T assembly and deployment system.

Sunflake XL can easily be adapted for deployable systems in microgravity. It could be used on any form of human lander, lunar outpost, or orbital stations. Any missions that require lightweight portable high efficiency PV energy could be of interest.   The structure can be modified for deployment on Mars or other planetary missions. It can be designed to accommodate different tracking angles, anywhere from vertical to horizontal. While it is currently designed for reliable re-deployment, a lighter single-deployment system can be easily developed. A modified Sunflake XL design could be used in a variety of terrestrial applications. It can be developed into a compact, re-deployable solar power generator. A stand-alone system could be deployed, programmed to track sun angles, and retracted remotely. We are exploring DOD and other applications for remotely re-deployable pop-up PV power generation, suitable for challenging terrain and conditions.

This is early/mid-stage (TRL 4) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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