Abstract

Deployable origami-based arrays offer significant advantages for space optical systems due to their ability to stow compactly and deploy to a large surface area. However, achieving the panel alignment precision required for optical applications remains an open challenge, particularly for non-rigid-foldable patterns such as the flasher, where large relative motion during deployment and geometric constraints at panel interfaces limit the effectiveness of traditional hinge designs. This thesis addresses the precision alignment challenge through the design, prototyping, and experimental testing of novel passive precision hinges for rigid-panel origami-based deployable space arrays. A compact kinematic coupling hinge incorporating Lamina Emergent Torsional (LET) joints, ball-and-groove Kelvin coupling features, and neodymium magnets was developed and evaluated across a progression of prototype configurations. An iterative design process was used, beginning with two-panel hinge prototypes, advancing to degree-four vertex mechanisms, and culminating in a full 26-panel flasher array. To improve the rotational stiffness of the coupling, an Extended-Arm configuration was developed that relocates the kinematic contact points away from the hinge axis, substantially increasing the area of the stability triangle and improving global array planarity without increasing the optical footprint of the panels. Across four design iterations, global alignment error was consistently reduced, with the final aluminum prototype achieving measurable improvements in best-fit plane deviation. A 3D scanning methodology using a 3D scan arm and 3D pointcloud software was developed to characterize panel-level alignment repeatability across repeated deployment cycles. The results demonstrate that passive precision kinematic couplings can be successfully integrated into a non-rigid-foldable origami flasher array and that the Extended-Arm geometry provides a meaningful geometric advantage for improving deployed alignment. This work provides a foundation for future high-fidelity optical deployable arrays and advances the understanding of precision hinge design for compact, volume-constrained environments.

Degree

College and Department

Ira A. Fulton College of Engineering; Mechanical Engineering

Rights

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