The purpose of this research is to develop fundamentals of compliant mechanisms in deployable space systems. The scope was limited to creating methods for thick origami, developing compliant deployable solar arrays, and developing methods for stowing and deploying the arrays. The research on actuation methods was focused on a one-time deployment of the array. Concepts for both passive and active actuation were considered. The primary objective of this work was to develop approaches to accommodate thickness in origami-based deployable arrays with a high ratio of deployed-to-stowed diameter. The HanaFlex design was derived from the origami flasher model and is developed as a deployable solar array for large arrays (150 kW or greater) and CubeSat arrays (60 W). The origami folding concept enables compact stowage of the array, which would be deployed from a hexagonal prism into a flat array with about a 10-times increase in deployed diameter as compared to stowed diameter. The work on the origami pattern for the solar array was also applied to the folding of 80-100 m2 solar sails for two NASA CubeSat missions, NEA-Scout and Lunar Flashlight. The CubeSat program is a promising avenue to put the solar array or solar sails into space for testing and proving their functionality. The deployable array concept is easily scalable, although application to CubeSats changes some of the design constraints. The thickness-to-diameter ratio is larger, making the issues of thickness more pronounced. Methods of actuation are also limited on CubeSats because of the rigorous size and weight constraints. This dissertation also includes the development of a compact, self-deploying array based on a tapered map fold design. The tapered map fold was modified by applying an elastic membrane to one side of the array and adequately spacing the panels adjacent to valley folds. Through this approach, the array can be folded into a fully dense stowed volume. Potential applications for the array include a collapsible solar array for military or backpacking applications. Additional compliant mechanism design was done in support of the HanaFlex array. This included a serpentine flexure to attach the array to the perimeter truss for deployment, and a bistable mechanism that may be used in the deployment of the array or sail.

Origami-based design is increasing in popularity as its benefits and advantages become better understood and explored. However, many opportunities still exist for the application of origami principles to engineered designs, especially in the use of non-paper, thick sheet materials. One specific area utilizing thick sheet materials that is especially promising is origami-based mechanisms that require electrical power transfer applications. Many of these opportunities can be met by the use of surrogate folds. This thesis provides methods and frameworks that can be used by engineers to efficiently select and design surrogate folds for use in origami-based mechanisms and products. Surrogate folds are a means of achieving fold-like behavior, offering a simple method for achieving folding motions in thicker materials. A surrogate fold is a localized reduction in stiffness in a given direction allowing the material to function like a fold. A family of surrogate folds is reviewed, and the respective behaviors of the folds discussed. For a specified fold configuration, the material thickness is varied to yield different sizes of surrogate folds. Constraint assumptions drive the design, and the resultant configurations are compared for bending motions. Finite element and analytical models for the folds are also compared. Prototypes are made from different materials. This work creates a base for creating design guidelines for using surrogate folds in thick sheet materials. As mechanisms with origami-like movement increase in popularity, there is a need for conducting electrical power across folds. Surrogate folds can be used to address this need. Current methods and opportunities for conducting across folds are reviewed. A framework for designing conductive surrogate folds that can be adapted to fit specific applications is presented. Equations for calculating the electrical resistance in single surrogate folds as well as arrays are given. Prototypes of several conductive joints are presented and discussed. The framework is then followed in the design and manufacture of a conductive origami-inspired mechanism.

Continuum manipulators which are robot limbs inspired by trunks, snakes, and tentacles, represent a promising field in robotic manipulation research. They are well known for their compliance, as they can conform to the shape of objects they interact with. Furthermore, they also benefit from improved dexterity and reduced weight compared to traditional rigid manipulators. The current state of the art continuum robots typically consists of a bulky pneumatic or tendon-driven actuation system at the base, hindering their scalability. Additionally, they tend to sag due to their own weight and are weak in the torsional direction, limiting their performance under external load. This work presents an origami-inspired cable-driven continuum manipulator module that offers low-cost, light-weight, and is inherently safe for human-robot interaction. This dissertation includes contributions in the design of the modular and torsionally strong continuum robot, the motion planning and control of the system, and finally the embedded sensing to close the loop providing robust feedback.

Continuum manipulators which are robot limbs inspired by trunks, snakes, and tentacles, represent a promising field in robotic manipulation research. They are well known for their compliance, as they can conform to the shape of objects they interact with. Furthermore, they also benefit from improved dexterity and reduced weight compared to traditional rigid manipulators. The current state of the art continuum robots typically consists of a bulky pneumatic or tendon-driven actuation system at the base, hindering their scalability. Additionally, they tend to sag due to their own weight and are weak in the torsional direction, limiting their performance under external load. This work presents an origami-inspired cable-driven continuum manipulator module that offers low-cost, light-weight, and is inherently safe for human-robot interaction. This dissertation includes contributions in the design of the modular and torsionally strong continuum robot, the motion planning and control of the system, and finally the embedded sensing to close the loop providing robust feedback.

Origami-inspired design is an emerging field capable of producing compact and efficient designs. The object of a surrogate fold is to provide a fold-like motion in a non-paper material without undergoing yielding. Compliant mechanisms provide a means to achieve these objectives as large deflections are achieved. The purpose of this thesis is to present a summary of existing compliant joints suitable for use as surrogate folds. In doing so, motions are characterized which no existing compliant joint provides. A series of compliant joints is proposed which provides many of these motions. The possibility of patterning compliant joints to form an array is discussed. Arrays capable of producing interesting motions are noted.

Origami-inspired and deployable technology has become increasingly common in a variety of applications including satellite and antenna designs for space applications. The drive to utilize ultra-thin materials in the design of these deployable space structures has led to the development of membrane hinges. Membrane hinges show promise as an effective surrogate fold because of their potential advantages including requiring minimal volume and mass, allowing for small bending radii, and functioning without lubricant. Two challenges associated with membrane hinges include reliability after repeated cyclic loading and predictability of a large deployable with radially-unconstrained membrane hinges. The research presented includes the cyclic testing and a design analysis of membrane hinges in deployable systems. Additionally, demonstrations of membrane hinges in a variety of applications are included.