Design and optimization of thin membrane tensioning for deployable space antennas

Thin and ultra-thin materials, such as Kapton foils or thin spread-tow carbon fabrics, are increasingly employed in spacecraft systems due to their low weight and high flexibility, which are suitable features for deployable reflector structures. However, these devices require a uniformly tensioned surface to ensure optimal signal reflection, which represents a challenging achievement due to the wrinkle formation induced by the tensioning process. This study investigates numerically and experimentally the mechanical behaviour of triangular Kapton foils subjected to a 3-point tensioning configuration. Moreover, a one-shot manufacturing process is proposed to realize the cable-membrane interface, conceived for minimizing surface defects and keeping membrane integrity.