AIAA-2001-1418

SOME MICROMECHANICS CONSIDERATIONS OF THE FOLDING OF

RIGIDIZABLE COMPOSITE MATERIALS
Thomas W. Murphey*, Troy Meink†, and Martin M. Mikulas‡
Air Force Research Lab, Kirtland Air Force Base, New Mexico

launch vehicle shroud. In the early 60’s, NASA flew

Abstract
There is considerable interest in the use of
composites with a softened matrix to improve the
compact packaging of structures for space applications.
It has been surmised that a soft matrix will enable a
composite to be bent to a much tighter bend radius than
is achievable with a normal stiff matrix. Over the past
30 years, numerous empirical attempts have been made
at developing what is commonly referred to as
rigidizable composites. These are composites for which
the matrix is in a softened state during packaging and
deployment, and then rigidized for use once deployed
in space. Although some success has been achieved
with various rigidizable processes, there does not exist
a basic understanding of the complex mechanisms
associated with the required tight folding or the limits
to which the folding can be achieved.
This paper explores the basic micromechanics
deformation mechanisms associated with the folding of
softened matrix composites. It is assumed that the
primary mechanism that enables the large deformations
associated with tight folding is micro-buckling of the
fibers in the softened matrix. The basic kinematic
relations that govern folds with micro-buckled fibers
are developed and used to quantify the associated
internal fiber motion and matrix strains. Experimental
results are presented that verify the assumed
micromechanics model and provide insight into the
level of folding that can be achieved with rigidizable
composites.
Introduction
Since early in the space program inflatable
structures have been considered as a means for
achieving a spacecraft on orbit that is larger than the
the 125 ft. diameter inflatable ECHO spherical
satellite.1 To maintain shape after initial pressurization,
the thin walled sphere was constructed of multiple
layers of Mylar and aluminum. During pressurization,
the aluminum in the wall was intentionally over
stressed to the point of yielding such that after the
pressure was gone, the “rigidized” sphere would
maintain its shape. In the years since that initial
success, NASA and the DOD have conducted
considerable research on the development of structures
made of filamentary composite with polymer resins.
Although numerous developmental structures have
been built from such rigidizable material systems, the
technology remains unused. One reason for the
material remaining unused is the lack of an underlying
fundamental technology database. An important aspect
of this technology database is a basic micromechanics
kinematics analysis of the large rotations and
deformations that are associated with compact
packaging of rigidizable composites.
The ratio of fold radius to material thickness
(hence forward called the bend ratio, β ) provides a
first order estimate of the packageability of a
construction system. Material failure strain directly
limits minimum bend ratio. Figure 1 shows two typical
fiber materials, there assumed failure strains, and their
subsequent minimum bend ratios. To be comparable to
traditional technology, rigidizable packaging schemes
must better the bend ratio possible with graphite-epoxy
laminates, approximately 50. Rigidizable and
traditional graphite-epoxy laminates employ similar
fibers limited to the same failure strains; simply
switching to a rigidizable resin system does not enable
a smaller bend ratio. Rigidizable composites have the
potential to enable deployable structure packaging

*
Research Engineer, AIAA member
†
Senior Aerospace Engineer, Senior AIAA Member
‡
Professor Emeritus, University of Colorado, Boulder, Colorado, AIAA Fellow
This paper is declared a work of the U.S. Government and is not subject to copyright protection in the United States.

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configurations that are denser and more versatile
(smaller bend ratios) because a soft matrix facilitates
more diverse fiber deformations modes. These new
deformation modes kinematically allow fibers to
achieve effective strains much greater than that of the
constituent fiber. This paper presents a
micromechanics analysis of the kinematics of folding
soft matrix composites. A deformation mode allowed
by soft resins, micro-buckling, is shown to
kinematically allow much greater effective strains and
hence, smaller bend ratios than non-rigidizable
materials. Experimental results supporting the analysis
and demonstrating the method are also presented.
The four major classes of resin systems being
considered for rigidizable structures are, thermosets,
UV cured, thermoplastics, and elastic memory
polymers.2 The thermosets and UV cured resins require
curing in space while the thermoplastic and elastic
memory resins are cured on the ground and only
involve reheating in space to allow deployment and
rigidization. This paper is concerned with the folding
of fiber composites while the resin is softened because
either it is not cured (thermoset and UV cured resins) or
the resin it heated (thermoplastic and elastic memory
resins). In order to make a rational design selection
among these resin systems, it is necessary to be able to
understand and predict the basic mechanics of fiber and
resin deformation of these systems during the
packaging and deployment process. This paper
develops the basic micromechanics of folding softened
composite systems, and provides a basis for comparing
different resin systems.
Kinematic Fold Models
The micromechanics of folding are well described
by the kinematics of deformations, regardless of the
forces responsible for them. To provide a first order
understanding of the severe deformations associated
with folding, a two-dimensional plane-strain kinematic
model is considered.
An infinite homogenous plate of thickness t is
assumed initially flat. It is then folded, back upon
itself, about a mid-plane radius r to form a 180 deg.
fold. Plate thickness is assumed to remain constant and
mid-plane strain zero throughout the process; bending
is accommodated purely through extensional strains
proportional to the distance from mid-plane. Further,
shear strain components parallel to plate surfaces are
assumed zero so that strains only occur within the
region of bending. This idealized, extensional fold is
illustrated in Figure 2. With the above assumptions, the
maximum strain required to construct the fold is a
function only of the material thickness and the bend
radius.
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As shown in Figure 2, the inside fold surface is of
length li = π ( r − t 2 ) while the mid-plane length
remains l = π r . The resulting difference in length
between the mid-plane ( l ) and the inside surface ( li )
is,
π
δ = l − li = π r − π ( r − t 2 ) =t. (1)
2
Strains on the inside (compressive) and outside (tensile)
surfaces are given by,
δ πt 2 t
ε= = = . (2)
l πr 2r
Casting Equation (2) in terms of the bend ratio ( β )
gives,
r 1
β= = . (3)
t 2ε
Equation (3) is graphed in Figure 1, illustrating the
limits of typical fiber materials. To achieve a
foldability significantly better than these materials, an
effective extensional strain on the order of 5% is
required.
To fully appreciate the magnitude of deformations
required for small bend ratio folding, it is revealing to
modify the previous assumptions from that of pure
extensional deformation to that of pure shear
deformations. Again, material thickness does not
change, however, extensional strain components
parallel to the surfaces are assumed zero and shear
strains are non-zero. As shown in Figure 2, the bending
is accommodated through shear deformations. Shear
strain is greatest at the ends of the fold where it is given
by,
!δ " !π "
γ = tan −1 # $ = tan −1 # $ ≈ 1 . (4)
t
% & % & 2
δ is evaluated using Equation (1). Regardless of fold
radius or material thickness, a shear strain of 100% is
required to accommodate folding. Lines initially
perpendicular to the plane of the lamina shear at an
angle of γ = 1 rad = 57.5° .
Two factors combine to prevent realization of pure
extensional and shear folds in soft matrix composites.
First, soft resins violate the assumption of zero shear
stiffness. As described in the extensional fold model, a
shear stiffness generates surface normal stresses that
resist shear deformations. These stresses have a
tendency to return the shear strain to zero far from the
fold region. Assume the limiting case of a shear fold
with all extensional strain occurring outside of the fold
region in the form of a 1% fiber strain. Normalization
of the shear strains requires extensional strains to be
distributed along 80 times the material thickness or 0.8
in. along a 10 mil thick plate.
 Second, continuous fibers are extremely slender Combining Equations (5) and (6) gives the maximum
structures that individually buckle under near zero effective strain a fiber can achieve through micro-
compressive loads. Only the matrix shear stiffness buckling,
prevents fibers from buckling.3 Fibers in soft matrix 1
composites have been observed to buckle under small ε effective = 2
(7)
2!
compressive stresses, indicating the lack of significant Rf "
1 + 4π # $
shear stiffness in soft resins. Once buckled, % λ &
considerable matrix strain compliancy is required to Equation (7) is graphed in Figure 6 for a range of
prevent matrix failure by separation. Soft resins also micro-buckle wavelengths. The plot reveals that with a
lack this compliancy and matrix separation generates a micro-buckle wavelength of 1.0 mm, an effective strain
crack-like geometry that can propagate into catastrophic
of 19% is possible for graphite fibers ( R f = 0.33 mm).
delamination of fold inner surface fibers. The severity
of delaminations required to accommodate a shear fold Laminate Folding with Micro-buckling
are illustrated in Figure 3.
In a micro-buckle fold, compressed fibers micro-
Micro-buckling buckle and exhibit a drastically reduced effective axial
Soft matrix composites are potentially highly stiffness. The effective axial stiffness of a sinusoid is
foldable because they allow fibers to accommodate a given by,5
bending deformation mode not allowed by stiff resins. σ Euler 2 EI ' π 2 1 1 (
Specifically, a soft matrix allows fibers to Eeffective = = ) + 2*, (8)
2ε effective A )+ 4 λ 2
ao *,
synchronously micro-buckle and take the shape of a
sinusoid (Figure 4). Local axial fiber strains are where EI is the fiber bending stiffness and A is the fiber
relatively small due to the minuscule loads required to cross-sectional area. Assuming a solid circular cross-
buckle fibers. Thus, the primary deformation mode of a section and λ >> ao , Equation (8) reduces to,
micro-buckled fiber is bending and axial strains need 2
not be considered. Eeffective 2I r fiber
= = . (9)
Due purely to bending, a sinusoid has an effective E Aao2 2ao2
extensional strain that depends on the ratio of the On the fold outside surface, fibers are in tension and
micro-buckle wavelength ( λ ) to amplitude (ao), given remain straight and axially stiff. In effect, the outside
by,4 fibers are axially rigid. As explained below, this large
1 discrepancy in stiffness forces the fold neutral axis
ε effective = 2
. (5)
(plane of zero extensional strain) very close to the
4 !λ "
1+ 2 # $ outside fold surface.
π % ao &
The reduced effective axial stiffness of buckled
Equation (5) is graphed in Figure 5 where it is apparent fibers allows them to be highly compliant without
that a micro-buckle amplitude to wavelength ratio of generating significant compressive stresses. The tensile
0.15 is required for an effective strain of 5%. There is fibers are opposite to this because their large axial
potential to achieve larger effective strains as the ratio stiffness results in large stresses for small strains. As
is increased. shown in Figure 7, to maintain moment equilibrium on
Micro-buckling could result in fiber breakage if the each side of the fold neutral axis, the neutral axis moves
sinusoid shape causes a bend radius smaller than the to the outside fold surface. In a fold accommodated
fiber is capable of. Table 1 lists typical composite through micro-buckling, the deformations occur
fibers, their assumed diameters, their assumed failure primarily through effective axial compression of micro-
strain, and the corresponding minimum radius around buckled fibers. This deformation mode is illustrated in
which they could be folded by Equation (2), Figure 7 and the corresponding bend ratio as a function
rmin = d fiber ( 2ε failure ) . The minimum fold radius is a of strain (assuming the neutral axis is the outside fold
surface) is now two times greater than the previous
fiber property that determines the limit of micro- case,
buckling and likely has a strong influence on the
r 1
foldability of a fiber/resin system. β microbuckled = = . (10)
t ε effective
The maximum curvature of a micro-buckled fiber
occurs at the sinusoid peak (or trough) and is given by, Equation (10) is graphed in Figure 1 as the region
λ 2 applicable to rigidizables. Combining Equations (7)
Rf = . (6) and (10) gives the minimum laminate fold ratio as a
π 2 ao

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function of minimum fiber bend radius and micro-
buckle wavelength,
2 effective strain is achieved, this mode can lead to early
!R "
β microbuckled = 1 + 4π # f $ .
2
(11)
% λ &
Equation (11) is graphed in Figure 8 for a range of
micro-buckle wavelengths. Assuming a wavelength of
1.0 mm and graphite fibers ( R f = 0.33 mm), a
theoretical minimum fold ratio of 5.3 is possible. The
validity of the analysis for a fold this tight is
questionable because the analysis assumes a bend
radius several times larger than the material thickness.
However, the results demonstrate that tight folds,
β <<50, are theoretically feasible with fiber micro-
buckling.
Micro-buckling Inter-Fiber Shear
The failure mode of interest may not be fiber
bending. A micromechanics analysis shows that
extreme inter-fiber shear strains are required to
accommodate fiber micro-buckling. As the fibers
micro-buckle, large interlaminar matrix shear strains
occur as shown in Figure 9. By assuming a sinusoidal
micro-buckling deformation, an expression for the
maximum interlaminar shear strain can be obtained as,3
'π a ! h "( π a ! h "
γ xy max = tan ) o # 1 + $ * ≈ o #1 + $ , (12)
−1
+ λ % 2c & , λ % 2c &
where h is the effective micromechanics thickness of
the fibers and 2c is the effective thickness of the matrix.
Using Equations (5) and (12), a quantitative assessment
of the interlaminar shear strains required to obtain a
given amount of effective compression strain is,
' ! h" ε ( ! h" ε
γ xy max = tan−1 )2 #1 + * ≈ 2 #1 + $
+) % 2c $& 1 − ε ,* % 2c & 1− ε
Equation (13) indicates that the shear strain increases as
the matrix thickness (2c) decreases. Thus, as fibers are
packed more densely (larger fiber volume fraction) the
shear strain required to accommodate a fold increases.
Assuming an effective matrix thickness of 1/10 the
fiber thickness, h 2c = 10 , Equation (13) indicates a
large shear strain of 144% is required to accommodate
a compressive strain of 10% ( β = 10 ). Lowering the
fiber volume fraction to an effective h 2c = 1 requires
significantly lower shear strains of 92% to
accommodate the same fold. Laminates with lower
fiber volume fractions may accommodate a micro-
buckle fold with a lower chance of matrix failure due to
inter-fiber shear.
Micro-buckling Modes
The folding of soft matrix laminates shows two
characteristically different fiber micro-buckling modes.
American Institute of Aeronautics and Astronautics
The first and most commonly observed mode is out of
plane buckling, as shown in Figure 7. While a large
lamina failure as the micro-buckles grow and eventually
result in matrix failure in the form of delaminations.
Another stability mode is in-plane buckling. In this
mode, the fibers deform sideways, remaining in the
plane of the material. Because the fibers remain in-
plane, delamination is inhibited and larger effective
strains may result.
Experiment observation has shown the lowest
mode to be out-of-plane. However, by applying a
compressive pressure to the inside fold surface, it is
theoretically possible to force the in-plane buckling
mode. An apparatus was designed and built to bend
laminates around a mandrel while applying a
compressive pressure (Figure 10). The pressure is
generated through an axial force (P) on the sample and
the compressive pressure σz is given by,
P
σz = , (14)
rw
where r is the bend radius and w is the width of the
sample. Experiments using this technique have had
moderate success at inducing in-plane buckling.
Experiment
A series of folding experiments were performed on
elastic memory resin laminates with graphite fibers
using the described apparatus. Tensile tests were used
to evaluate fiber breakage, with the assumption that
large numbers of broken fibers show up as a reduction
in sample tensile strength. Matrix integrity was
evaluated with fixed-fixed end condition buckling tests.
Because it is predominantly the matrix that prevents
. (13) local fiber buckling, a degraded matrix should show as
a decrease in buckling strength.
The test protocol was to first elastically buckle a
sample before it was folded. Then fold the sample
using the bending apparatus. After full cooling, the
samples were reheated to return them to a flat
(deployed) state and cooled again. The buckling test
was repeated and finally, the samples were pulled to
determine ultimate tensile strength. For comparison of
the tensile test results, a control group was pulled
without going through the folding process.
Typical buckling test results are shown in Figure
11. For the test shown, the folding process (bend ratio
of 10) degraded the load carrying capacity of the
sample by 21%. The tensile testing of ten samples (5
pristine and 5 folded to a bend ratio of 20) showed a
15.7% reduction in strength. In all tests, combinations
of in-plane and out-of-plane micro-buckle modes were
observed.
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 Concluding Remarks
This paper explores the basic micromechanics of
deformation mechanisms associated with the folding of
composites with a softened matrix. It is assumed that
the primary mechanism that enables the large
deformations associated with tight folding is micro-
buckling of the fibers in the softened matrix. The basic
kinematic relations that govern the large deformations
associated with tight folding are developed and used to
quantify the associated internal fiber motion and matrix
strains. Experimental results are presented that verify
the assumed micromechanics model and provide insight
into the level of folding that can be achieved with
rigidizable composites.
It is shown that compressive strains associated with
laminate bending on the order of 5% are required to
achieve compact packaging. This very high
compressive strain is enabled by micro-buckling of the
fibers in a soft matrix. It is also shown that matrix
shear strains in excess of 100% are induced as a
consequence of these large compressive strains.
Experimental studies indicate that the mechanism of
micro-buckling allows softened matrix composites to be
folded to very small bend ratios. Experiment also
revealed that the folding process can degrade tensile
strength and buckling strength.
References
1
Elder, E. C., "Out from Behind the Eight-Ball: A
History of Project Echo," AAS History Series, Volume
16, 1995 by American Astronautical Society.
2
Tupper, M., Munshi, N., Beavers, F., Gall, K.,
Mikulas, M., and Meink, T., “New Developments in
Elastic Memory Composite Materials for Spacecraft
Deployable Structures and Components,”
Proceedings of the 42th AIAA/ASME/ASCE/AHS/ASC
Structures, Structural Dynamics, and Materials
Conference and Exhibit, April 16-19, 2001, Seattle,
WA.
3
Jones, R. M., "Mechanics of Composite Materials,"
Hemisphere Publishing Co., Taylor and Francis,
1975.
4
Murphey, T. W., "A Nonlinear Elastic Constitutive
Model for Wrinkled Thin Films" Ph. D. Dissertation,
University of Colorado at Boulder, 2000.
5
Murphey, T. W. and Mikulas, M. M., Jr., "Nonlinear
Effects of Material Wrinkles on the Stiffness of Thin
Polymer Films," Proceedings of the 40th
AIAA/ASME/ASCE/AHS/ASC Structures, Structural
Dynamics, and Materials Conference and Exhibit,
April 12-15, 1999, St. Louis, MO., AIAA 99-1341.

Table 1: Minimum bend radius and maximum effective axial strain due to micro-buckling.
Assumed Assumed Calculate Maximum Axial Minimum Micro-
Fiber Failure Fiber Minimum Fiber Micro-buckle Strain buckled Bend
Strain Diameter Bend Radius, Rf ( λ = 1.0 mm) Ratio
Graphite 1.0% 6.5 µm 0.33 mm 19% 5.3
Fiberglass 1.5% 3.0 µm 0.10 mm 72% 1.4

100

50 Gr/Ep
Fiberglass
r
t
Bend Ratio, β =

20 r 1
=
t ε
10
r 1 Rig
= idi
zab
5 t 2ε les

0.01 0.02 0.05 0.1 0.2 0.5

Strain, ε
Figure 1: Achievable bend ratio as a function of strain.

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 l =πr

li = π (r − t 2 ) Extensional
Fold

Flat
Plate

57.5°
Shear
δ Fold
t

δ  π 
tan −1   = tan −1   = 57.5°
t 2
Figure 2: Shear and extensional folds and their assumed deformations.

Figure 3: Simulation of fiber buckling and the ensuing delamination observed in soft resins under
compression.

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 l

df ao Rf

Figure 4: The sinusoid profile of micro-buckled fibers.

0.4

0.35
1
0.3 ε= 2
4 λ
1+ 2  
ao 0.25 π  ao 
λ 0.2

0.15
λ
0.1
ao
0.05

0.05 0.1 0.15 0.2 0.25

Strain, e
Figure 5: Effective strain due to bending in a micro-buckled fiber.

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 0.4

0.35 1
ε effective = 2
R 
0.3 1 + 4π  f 
2

 λ 
0.25 Gr/Ep
ε effective

0.2
l = 10 mm
0.15
5.0
0.1
2.0
0.05 1.0
0.5
0.2
0.5 1 1.5 2 2.5 3 3.5 4
R f (mm)
Figure 6: Theoretical maximum effective strain due to micro-buckling as a function of minimum fiber
bending radius for various micro-buckle wavelengths.

Stress Profile

lo = π (r + t 2 ) Tensile
Stresses
l − l π (r + t 2 ) − π (r − t 2 ) t s t
ε= o i = = l =πr
l πr r
Compressive Neutral
Stresses Axis
li = π (r − t 2 )

Figure 7: Out-of-plane micro-buckle fold deformation mode and stress profile.

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 40
l = 0.2 l = 0.5 l = 1.0
35 l = 2.0
30
r
t
Bend Ratio, β =

25

20

15 Graphite
10
l = 5.0
5
l = 10

0.25 0.5 0.75 1 1.25 1.5 1.75 2

Rf
Figure 8: Bend ratio as a function of minimum fiber bend radius and micro-buckle wavelength.

Figure 9: Inter-fiber shear strains.

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 Mandrel

Test Specimen

Constant Force Spring

Figure 10: Experimental apparatus for folding soft matrix composite laminates while inducing the in-plane
micro-buckling mode.

2000
Before Folding
1800 (6 Trials)
1887 Psi

1600
Axial Compressive Stress (Psi)

1400
1490 Psi
Folded Once
1200
(6 Trials)

1000
Buckling Test Specifications
All tests performed on same specimen
800
0,0,0 layup
Jog attributed to unidirectional IM7 graphite fabric
600
removal of test 40% fiber volume fraction
apparatus play when Cross section 0.70 x 0.050 in
400 Active Length 5.75 in
fixed-pinned buckle
mode occurs. Fixed-fixed end conditions
200

0
0.000 0.001 0.002 0.003 0.004
Axial Strain

Figure 11: Buckling tests results before and after folding demonstrate a 21% reduction in load carrying
capacity.

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