Expandable/Foldable Structures for Habitat

Folded Structures Company (FSC) has developed an innovative design approach for multi-laminate, primary and secondary structures for planetary habitats that integrates the dynamic deployment means with the static structural design using an advanced mathematical folding theory. The design approach holds the promise of a much simpler expandable structure that is both lightweight and compactable (low delivery volume) and yet capable of extending into an expansive volume. FSC research supports the utilization of a new class of deployable, space-based structures that utilize an advanced folding methodology as the primary engineering and assembly method combined with the use of both single and multi-laminate sheet materials. The proprietary patterning algorithms create tessellations for planar sheets that articulate dynamically on the edges of the tessellation allowing for uniform deployment across the entire sheet. Previous to the development of these algorithms, there was no general system for generating doubly periodic folded structures. Based on results from a previous NASA SBIR project, FSC will apply its proprietary folding techniques and software to the broad topic of expandable habitat structures. The Phase I project has resulted in a design concept for the expandable bladder section of the proposed lunar habitat that also integrates the flooring into a single deployable structure.

Material folding lends itself to a number of applications from very sophisticated (aerospace) to the ordinary such as packaging materials. Kraft paper cores based on the folding techniques could yield a superior product to corrugated cardboard. Multi-layer blocks made from recyclable materials could replace Styrofoam for use in space filling and shock absorbing. For aerospace using aluminum or composite materials, the folded structures could improve upon the existing honeycomb cores, which are used throughout the airplane in the floors, luggage compartments, and wings. For the transportation industry, aluminum or steel folded tessellations in flat laminated panels could be used for high strength but lightweight truck beds. Folded materials could be specifically designed for automobile floors to give a resilient strength to the frame while also serving to dampen the overall vibrations of the automobile. The lightweight strength and energy absorbing properties are also suited for bumpers, hoods, and crash protecting car doors. On highways, new crash barriers may be possible because of their low cost and high-energy absorption.

The innovative folding method will make possible a technical break-through in tessellated architectures for expandable structures for planetary habitat applications. The new technology offers diverse capacity to design, manufacture, and self-assemble doubly periodically folded sheet material into structures that are lighter and more compactable than provided by current engineering practices. Some space-based applications include solar arrays, parabolic reflectors, sun and radiation shielding and extendable masts and booms. In addition to inflatable architectures, other strategies (including solar heating/radiation, elastic memory, and mechanical force) can be employed for self-activating and sustaining the unfolding process.

This is early/mid-stage (TRL 5) — 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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