Performance evaluation of additively manufactured deployable kresling pattern capability for spacecraft modules model under cyclic loading using thermoplastic polyurethane

The problem of limited space in spacecraft presents a significant challenge for scientists worldwide, which can be addressed using deployable structures such as the foldable Kresling pattern. Deployable structures offer a critical solution to the spatial constraints inherent in spacecraft design, with the Kresling pattern providing significant potential for lightweight, foldable modules. This study aims to evaluate and compare the mechanical durability of single-layer and two-layer Kresling patterns fabricated from Thermoplastic Polyurethane 95A under repeated loading. The patterns were additively manufactured using Fused Filament Fabrication with optimized parameters, including 100 infill and a 30 mm/s print speed, and subsequently subjected to 100 loading cycles. The results revealed that the one-layer pattern sustained a higher maximum load 20.85 kg than the two-layer configuration 13.29 kg. After 100 cycles, the one-layer pattern�s load capacity decreased by 43.85, whereas the two-layer pattern showed reductions of 49.73 in top layer and 26.07 in bottom layer. Scanning Electron Microscope (SEM) analysis confirmed that both configurations maintained their structural integrity without failure. This research concludes that both configurations exhibit monostable behavior, providing crucial empirical data on the cyclic performance and durability of Kresling patterns, thereby validating their suitability for deployable spacecraft applications. © The Author(s), under exclusive licence to Springer Nature Switzerland AG 2025.