As part of a research project, a CFRP support structure was developed for a foldable solar sail for energy generation in space. This structure must meet strict require-ments with regard to the temperature range in space and the maximum thickness of the composite material. When folded, the solar sail is transported into space with minimal volume and unfolds independently.

The foldability of the structure requires exact material characterization and precise application of several successively applied matrix materials to a continuous fibre reinforcement material. The innovative production technology ensures both the mechanical integrity and the electrical performance of the solar cells. The combination of the process with specially selected materials is crucial in order to realize a composite material with optimal flexibility and stability. Material selection includes analysis using DSC, DMA and dilatometer. Folding tests are also essential.

By integrating advanced materials and optimized production processes, an efficient and scalable solution for flexible solar energy applications in space is achieved. The serial process technology developed in the project can also be used for many other applications where lightweight construction, multi-functionality and reliability are crucial, especially where a folding or unfolding function is beneficial. In addition, the multi-matrix material series process can be applied to a wide range of fibers and matrix materials. Products with different properties of the matrix material, such as local electrical conductivity or parts with different heat resistance, can be used. The process combines the advantages of ease of use, low-cost tools and very easy adaptability in terms of geometry and material combinations.

Keywords: Multimatrix, functional integration, self-development, composite.