Researchers at the University of Illinois Urbana-Champaign have made a significant breakthrough in space technology with the development of lightweight, deployable electromagnetic waveguides inspired by origami folding techniques. This innovative design aims to replace traditional heavy metal waveguides, which are not ideal for space applications, with flexible alternatives that can be compactly launched and expanded in space.
Xin Ning, a professor in the Department of Aerospace Engineering, led the project alongside his graduate students, Nikhil Ashok and Sangwoo Suk. The team began exploring the potential of origami for electromagnetic waveguides after a conversation between Ning and former colleague Sven G. Bilén at Penn State. The idea was to create waveguides that maintain a rectangular cross-section, similar to conventional designs, while taking advantage of the lightweight and space-efficient properties of origami.
In their research, Ning likened their simplest design to a brown paper shopping bag, where the rectangular base serves as a flange. The students then expanded on this concept, creating a foldable tube structure with two sections resembling a shopping bag, which allowed for both inlet and outlet connections. As they advanced their designs, they developed more complex shapes resembling bellows, which provided the necessary flexibility and functionality.
The fabrication process involved printing patterns onto large paper, laminating them with kitchen aluminum foil, and folding them into the desired shapes. For practical applications in spacecraft, the team envisions using 3D-printed durable materials, coated with high-quality commercial materials like Kapton and metal laminates to enhance performance.
Ning emphasized that their designs were meticulously modeled based on existing commercial waveguide structures to ensure performance comparability. He noted, “With the first bellows shape, we knew we had a foldable, deployable design that could perform, but we wanted to explore more possibilities with origami principles.” This exploration included simulating different distances and angles to achieve a 90-degree twist from input to output.
As the team tested their models, they encountered challenges during the deployment process. Ning recounted that after a few inches of easy deployment, the structure would sometimes become stuck. This prompted an in-depth analysis of the mechanics involved, leading to a realization that the load on the model increased significantly once it reached a certain point, risking the integrity of the design.
Through rigorous experimentation, the team established the maximum lengths for their waveguides, ensuring that the number of folds was optimized to minimize energy loss. Their ongoing research has led to a pending patent for this innovative technology.
While the primary focus has been on applications for spacecraft, the principles behind these origami-inspired waveguides have broader implications. The technology could also benefit naval, electrical, and communication systems where efficient microwave energy transfer is essential.
The findings of this study, titled “Shape-morphable origami electromagnetic waveguides,” were co-authored by Ashok, Suk, Ning, and Bilén, and published in Communications Engineering, part of Nature’s portfolio in March 2025. The research opens new avenues for lightweight, efficient structures in various sectors, showcasing the versatility and potential of origami in engineering.
