From Paper Origami to Flight Structures: A Review of Thick-Panel Origami-Inspired Deployable Aerospace Systems

Abstract

Origami-inspired deployable structures have become an important topic in aerospace engineering, mainly because they offer a practical way to store large structural surfaces within limited launch volumes and deploy them when needed. Paper origami shows that carefully arranged crease patterns can produce efficient and controllable shape changes. However, this idealised form of folding cannot be transferred directly to aerospace structures. Most classical origami theories are based on zero-thickness sheets, whereas flight structures are made from finite-thickness panels, mechanical hinges, structural skins, joints, frames, and load-bearing materials. Once these engineering features are introduced, the design problem changes significantly. For aerospace applications, the main question is therefore not only whether an origami pattern can fold, but whether its geometric principle can be developed into a structure that remains compact, stiff, reliable, and functional after deployment. This review follows the development from paper-based origami concepts to thick-panel origami-inspired deployable systems for aerospace use. It considers representative applications including deployable solar arrays, foldable structural panels, morphing aircraft components, and lightweight load-carrying systems. Particular attention is paid to panel thickness, since it influences crease-line arrangement, packaging efficiency, hinge design, deployment sequence, and manufacturing tolerance. Overall, thick-panel origami offers a feasible way to bring origami principles closer to flight-ready aerospace structures. Even so, wider aerospace application still depends on further progress in hinge integration, locking mechanism design, fatigue resistance, assembly accuracy, and ground-test validation.