A bistable composite cylindrical shell is a thin-walled structure that can change shape between two stable configurations under small energy input, showing great potential to be applied to space deployable mechanics. The internal stress level within a cylindrical shell plays a vital role in determining its morphing mechanics, whilst tailoring the internal stress is tricky for traditional composite manufacturing methods. In this paper, we devise a novel biaxial elastic fibre prestressing (EFP) method to systematic design and produce prestrained carbon-based composite cylindrical shells, with tailorable bistability and morphing mechanics, as well as improved load-carrying capabilities. A biaxial fibre stretching rig was devised to apply tensions on both directions of a plain-weave carbon prepreg simultaneously; prestrained cylindrical shell samples were produced with various prestrain levels to fully evaluate the fibre prestraining effects; a finite element model was established and showed good agreement with experimental observations. The fibre prestraining mechanisms were then proposed. It is found that EFP is effective in tailoring the internal strain/stress level within a composite cylindrical shell, which in turn altering the structural morphing mechanics, and able to significantly lower the maximum tensile strain during shape-changing, thus improve the load-carrying capability. These findings are expected to facilitate structural design of the deployable composite structures and flexible mechanical hinges, by allowing further design freedoms in terms of morphing mechanics and load-carrying capability.
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