Design, optimization, and validation of a bistable modified Kresling origami structure for deployable space capsules

The multi-stability of non-rigid origami-based structures, such as Kresling origami structures, has shown great potential for creating deployable and adaptable engineering systems. This study explores the design and optimization of a deployable, bistable origami structure using a modified Kresling crease pattern. By introducing truncations between layers, the traditional Kresling design is adapted into a multi-layer deployable structure with integral bistability. A parametric model of the modified structure was developed, enabling visualization and optimization of design parameters. Non-Dominated Sorting Genetic Algorithm II (NSGA-II) was applied to optimize the folding ratio and energy barrier, identifying configurations that were compact when folded and easier to deploy. Numerical simulations validated the bistable behavior, confirming structural stability after folding and deploying. Scaled models were tested for deployability through inflation and load-bearing capacity under puncture conditions to verify practical functionality. The results demonstrate the structure’s robust bistability and its ability to withstand internal pressure variations. These findings suggest that the modified Kresling origami structure is promising for applications in inflatable-deployable space capsules and habitats.