Origami Waveguides Could Revolutionize Satellite Design

Satellites could soon launch lighter and cheaper thanks to engineers who borrowed an idea from paper shopping bags.

Researchers at the University of Illinois Grainger College of Engineering developed electromagnetic waveguides that fold origami-style for launch, then unfold in orbit. The breakthrough could transform how we build spacecraft by replacing heavy metal tubes with flexible, foldable alternatives.

Traditional satellite waveguides are bulky metal tubes that transfer energy between components. They're heavy, rigid, and eat up valuable space during launch when every ounce matters.

Professor Xin Ning and his graduate students Nikhil Ashok and Sangwoo Suk took inspiration from an unlikely source: rectangular paper shopping bags. The bag's foldable bottom gave them the idea for creating waveguides that maintain their rectangular shape while collapsing flat.

The team started simple, designing waveguides with two shopping-bag-like sections that fold together. They then advanced to bellows-shaped designs that can twist and bend at precise angles as they deploy.

To test their concepts, the students printed patterns on large paper, laminated them with aluminum foil, and carefully folded each prototype by hand. The process was tedious, but both students mastered the intricate folding technique.

For actual spacecraft, the waveguides would be 3D printed from durable materials and coated with commercial-grade products like Kapton and metal laminates. The team modeled their designs on existing commercial waveguides to ensure fair performance comparisons.

The team hit a snag when testing their twisting designs. After deploying smoothly for a few inches, the waveguides would suddenly lock up. Detailed analysis revealed the problem: when stretched to the point where creases flatten completely, the force could break the material.

The Ripple Effect

This discovery led to mathematical equations that predict exactly how many folds are needed for any given distance. Now engineers can design waveguides that reach their target length with optimal efficiency and minimal energy loss.

The technology already has a pending patent. While originally designed for spacecraft, these foldable waveguides could improve naval systems, electrical infrastructure, and communications networks anywhere microwave energy needs transferring.

The innovation addresses a fundamental challenge in space exploration: launch costs are determined largely by weight and volume. Lighter, more compact components mean more room for scientific instruments and lower costs per mission.

Future satellites equipped with origami waveguides could carry more equipment, travel farther, or simply cost less to send skyward, all thanks to the humble paper shopping bag that inspired a space-age solution.