Design and testing of a precision coupling for origami-based arrays

Abstract

Creating ways to achieve precision positioning in large-motion deployable origami-based systems through improving accuracy and repeatability in the deployed state could enable better performance and new applications, such as optics. Precision positioning of origami-based arrays can be a challenge because of the high number of interconnected panels, large motion between stowed and deployed states, and challenge identifying volumes for precision alignment systems given the thin aspect ratio of the panels. This work introduces and tests a design for a precision coupling suitable for origami-based deployable arrays. The coupling is placed in a Z-fold mechanism and in two degree-four vertex (D4V) mechanisms, which are fundamental components of many origami-based arrays. The alignment and repeatability of these mechanisms are tested using a 3D scanner and the best-fit plane. The Z-fold mechanism has a repeatability of about 0.50° and 0.50 mm, and the D4V mechanisms have a repeatability of about 0.15° and 0.50 mm. These values show potential for certain optical applications and demonstrate that precision couplings can be implemented in origami patterns to increase performance of origami-based arrays.