Kinematics-driven design of reconfigurable bistable hinges with high stiffness and stability

Composite tape springs are curved shells with the ability to assume two energetically stable states. By carefully selecting layup and mold during manufacturing, these structures can store significant strain energy, making them ideal for deployable systems. Yet, their potential as reversible reconfigurable structures, particularly as adaptive hinges, remains largely unexplored. In structural applications, both stable states of these hinges must exhibit high stiffness to support loads while retaining the capacity for reversible reconfiguration. This paper introduces kinematics-based stacking concepts aimed at enhancing the stiffness of bistable hinges in both states, allowing for specific fold angles without compromising compliance. These designs leverage snap-through kinematics, resulting in unique architectures with customizable stiffness and stability. Additionally, the paper presents a novel energy-based semi-analytical approach for analyzing the stacking concepts. This approach involves constrained exploration of the energy landscape to assess the design space in terms of stiffness and energy barriers. Through comprehensive parametric studies, the research demonstrates significantly increased stiffness and reduced peak stresses compared to single tape spring designs. This research highlights the potential of employing tape springs as reconfigurable load-bearing structures in diverse applications, including precise adjustments of low-mass payloads like solar panels or antennas on space structures.