Integrated electrical connections in deployable composite tube flexures
File(s)
Published online version
Author(s)
Progida, Alberto
Santer, Matthew
Type
Journal Article
Abstract
This study extends the functionality of ultra-thin carbon fibre composite tube flexures by interleaving a multi-layered conductive film along the laminate’s midline to enable data and power transmission across the structural joint. Conductive tracks, created by silver nanoparticle deposition onto a polymide substrate, are encapsulated by a thermoplastic film to prevent short-circuits with the carbon fibres. The paper first establishes the mechanical stability of the integrated struc ture through analysis and testing, then investigates the electrical signal integrity and the feasibility of thermal actuation for a shape-memory use-case. Repeated moment-rotation tests showed a progressive reduction in locking moment. The conductive track remained functional, without showing an appreciable degra dation in signal quality or electrical resistance. Resistive heating tests reaching higher temperatures caused adhesive failure between the thermoplastic film and the tracks in the stowed state, leading to local delamination and catastrophic failure of the laminate. These findings demonstrate that novel inkjet-printed conductive interleaves are a viable solution for digital signal and low-power transfers in laboratory conditions, raising the challenge of extending testing to space-like environments and improving the bond strength of the silver tracks for enhanced thermal durability. This methodology represents a significant step forward in terms of structural power integration, enabling ultra-lightweight harnesses to be directly integrated within highly strained deployable members with applications on small and large satellites, as well as next generation space structures, such as space-based solar power stations.
Date Issued
2026-02-13
Date Acceptance
2026-01-07
Citation
CEAS Space Journal, 2026
ISSN
1868-2502
Publisher
Springer
Journal / Book Title
CEAS Space Journal
Copyright Statement
© The Author(s) 2026 Open Access This article is licensed under a Creative Commons Attribution 4.0 International License, which permits use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons licence, and indicate if changes were made. The images or other third party material in this article are included in the article's Creative Commons licence, unless indicated otherwise in a credit line to the material. If material is not included in the article's Creative Commons licence and your intended use is not permitted by statutory regulation or exceeds the permitted use, you will need to obtain permission directly from the copyright holder. To view a copy of this licence, visit http://creativecommons.org/licenses/by/4.0/.
License URL
Publication Status
Published online
Date Publish Online
2026-02-13