Multidisciplinary Design Optimization of Shape Programmable Space Structures

Ultra-lightweight space apertures require structural concepts that exceed deployable packaging limits. A recently proposed elastic snap-through shaping approach uses bistable composite unit cells to form programmable, coilable feedstock, avoiding the mass and power limitations of conventional in-space manufacturing and assembly. This paper develops a comprehensive multidisciplinary design optimization framework for these programmable cellular architectures. A single bistable unit cell, acting as a surrogate for the metastructure, is analyzed using nonlinear finite element simulations to characterize its mechanical response and actuation capabilities. A Gaussian Process Regression surrogate model is constructed to enable rapid evaluation of the high-dimensional design space. Particle Swarm Optimization is then employed for both single-objective maximization, and multi-objective trade-off analysis using an epsilon-constraint Pareto-front method. The optimized designs reveal distinct families that balance stability, actuation energy, and manufacturability. Sensitivity studies further identify the geometric parameters that exert the strongest influence on system performance. The proposed methodology provides a mission-relevant optimization framework for shaping large, deployable, and reconfigurable space structures.