Review and evaluation of warp-knitted patterns for metal-based large deployable reflector surfaces

Abstract A large deployable reflector antenna (LDA) is comprised of numerous components. One of the key components of this reflector antenna is the reflector surface. Several types of reflector surfaces have been developed and used, namely, metal mesh-based reflector surfaces, membrane-based reflector surfaces, etc. The benefits presented by warp-knitted metal mesh-based reflector surfaces are their foldability and light weight structural characteristics. Typical metal mesh-based reflector surfaces are produced using a warp knitting textile manufacturing process. A warp-knitted metal mesh reflecting surface is an elastic, open structured knit with a low bending stiffness produced on a high gauge knitting machine (E26 or higher gauge) consisting of a compatible metal yarn (typically tungsten or molybdenum). This paper gives an overview about the requirements for mesh reflector surfaces stated in the literature. Afterwards, an overview of different patterns currently investigated by the LDA community is given. The names given to the various types of patterns in the literature often differ. The construction of the various patterns is therefore first optical analysed and compared. Subsequently, the different patterns are evaluated on the basis of the requirements. Based on the requirements and the possibilities of the warp knitting machine, new possible patterns are identified and evaluated. For the development of a new reflector surface, the identified patterns are developed as a warp-knitted spacer fabric. This decision increases the stiffness of the knitted fabric. This new concept for an advanced reflector surfaces is introduced by Large Space Structures GmbH (LSS) (concept) and ITA (production technology).