Design and Dynamic Analysis of Rigid Foldable Aeroshells for Atmospheric Entry

Abstract

A novel rigid deployable aeroshell architecture has been developed, where rigid panels with a thermal protection system layer are connected between retractable ribs. Following origami principles, an optimal fold pattern is selected and imposed on the panels to ensure efficient flat stowage during launch and repeatable deployment. The design process includes minimizing the number of folds to reduce stacking height and maximizing the angles between each fold line to avoid an unfavorable aerothermodynamic response. The dynamic behavior of the optimal design is analyzed with the aid of a dynamic multibody analysis model. Results from the dynamic model show that the process of deployment is highly sensitive to panel geometry (especially panel thickness and hinge design). Robust, repeatable, and controllable deployment is most readily achieved with a small (but nonzero) panel thickness and selection of interpanel hinges, which allow a degree of over-rotation, avoiding a premature hard stop, which would otherwise prevent full deployment. Modeled results have been verified through experimental testing of a 0.4-m-diam scale model.