Proof of Concept for a Novel Ultralight Pneumatic Telescopic Boom Fabricated via Additive Manufacturing for Space Applications

This study investigates the performance characteristics of a six-segment telescopic boom prototype, two meters in length, entirely fabricated through additive manufacturing using composite materials, with the aim of optimizing the system’s strength-to-weight ratio. To meet the requirements for lightweight and high-stiffness space structures, the study focuses on validating the concept from these perspectives. The current assembly prototype weighs 2154 g for a deployed length of 2 m and a stowed length of 428 mm. The pneumatic extension system demonstrated an average pressure response ranging from 0.40 bar to 1.36 bar under a payload of up to 7370 g. At this threshold, an average inclination of 5.96° and an average deployment time of 60 s were recorded. Under an increased payload of 11,345 g, the prototype exhibited an average inclination of 1.1° and an average deployment time of 30 s, with only three segments fully deployed. This limitation is attributed to the maximum allowable internal pressure of the pneumatic tube, approximately 2.2 bar, where the high frictional and binding forces between the segments exceeded the available pneumatic energy, prematurely interrupting the extension cycle. These findings confirm the applicability of additive manufacturing to complex deployable systems and establish the mechanical and pneumatic performance limits of this prototype.