The Pyramid Hinge is an origami-inspired folding mechanism that allows flat panel-based designs to unfold into rigid three-dimensional structures. The patented mechanism was originally applied to smaller applications, such as foldable furniture, where its robust geometry enabled super-compact, flat designs.

The Pyramid Hinge Array is a combination of Pyramid Hinge units that are deployed or retracted by a central motorized movement. This design was featured in the original Sunflake 10kW design.

The array can be designed with varying numbers of subdivisions. It supports the option for a fully open flat position that is less than 360 degrees, and it can also be developed for non-flat (dome-shaped) deployed structures.

In the XL hinge design, a single power source enables the deployment and retraction of the entire array in both linear and radial directions. In the current 50kW Sunflake XL, three levels of the extension arm support three levels of folded flexible solar array gores that overlap when stowed.

• Ultra compact
• Re-deployable or single deployable
• Lightweight and robust integrated structure permits 2-axis tracking

• Two-axis tracking: Precisely positions the array horizontally and vertically for optimal solar exposure
• Scalable: Compact, nested design can be adapted for small- to large-scale arrays
• Energy-efficient: Minimizes power required for deployment and operation
• Balanced motion: Evenly distributes loads during deployment and retraction to reduce structural stress, which is important for large-scale designs

• Lunar and planetary surfaces: Compact and robust design with a lightweight internal structure can provide optimal performance on lunar and other planetary surfaces, where different gravitational or other forces are present.
• Orbit: Large deployable orbital constellations
• Low Earth orbit: Large arrays for space data centers
• Thermal rejection: Modified designs can be developed for use as thermal rejection systems
• Non-flat structures: Reflectors, antennas, etc.

A key component of UC3T and UC4T is a robust, lightweight mast mechanism that can move in two directions. Moving in one direction lifts the legs and base. Once the legs are deployed, it changes direction and lifts the payload (the array). The patented design enables stable vertical  deployment and clear passage of the rover underneath the deployed structure. The two-way mast also enables the deployed height to be doubled with a single mechanism.

The pyramid hinge geometry provides lateral reinforcement for a compact, lightweight leg structure.

• Mass-optimized: Compact, lightweight design reduces launch and transport costs
• Redeployable: Delivers consistent performance across repeated deployment cycles
• Terrain-stable: Wide, adaptive base maintains stability on uneven surfaces
• Dust-resistant: Supports new technologies under development to address lunar dust contamination of moving components
• Leveling capabilities: Stable deployment on angled surface terrain of 15 degrees or more

Deployable communication towers

The Sunflake/UC3T/UC4T assemblies are currently adapted to work with the Astrolab Flex Lunar Rover, creating a comprehensive automated deployment, retraction, transportation, and storage solution for solar array systems.

The lightweight container and control center protect the solar assembly from dust and debris during transport on the lunar surface. The array can also be deployed directly from the rover, without utilizing the leg structure.

• Portable: Designed for easy transport, rover deployment, and maintenance
• Deployable: Features an automated deployment sequence, level correction, and sun tracking
• Grid-Ready: Designed for seamless connection to future lunar power infrastructure with easy maintenance access

The SDS can be adapted for:

• Any manned or unmanned surface transporter on both lunar and other planetary surfaces
• Transporting communication towers
• Deployable structural frames for lightweight shelters
• Other deployable structures

Folditure Space Sunflake systems are lightweight, compact, robust, re-deployable Solar Power sources, developed with funding from NASA SBIR awards: