Novel bundle folding deployable mechanisms to realize polygons and polyhedrons.

• A new 7R unit is proposed to design pyramid and frustum mechanism. • A new RRR chain is proposed to fold the frustum into a bundle. • A general frame is proposed to design 1 DOF deployable mechanism. • Two methods are proposed to fold a polyhedron into a bundle. In this paper, a series of deployable polygon mechanisms (DGMs) and deployable polyhedron mechanisms (DPMs) are proposed. Firstly, we propose a new plane-symmetric 7R unit with folded lateral edges. Kinematics and suitable parameter values are calculated to realize full expansion. N-pyramid and N-frustum and a larger DPM are designed. Secondly, we propose a new RRR chain to connect existing deployable units. Threefold Bricard mechanism and alternative Bennett mechanism are used as two examples to fold triangular and square frustum into a bundle. Thirdly, we propose a general frame to design 1 DOF deployable mechanism based on the continuation method. Three improvements in accuracy, speed, and generality are made. Feasible points of general and special N-side DGMs are calculated (3≤N≤7) based on plane-symmetric hexagon 6R and heptagon 7R mechanisms. Our results not only unify most deployable units but also design many new ones and reconfigurable DGMs. Fourthly, we propose the polyhedron net method and the least joint angle method to fold a polyhedron into a bundle and reduce the number of links, joints, and DOF. Many DPMs are designed. [ABSTRACT FROM AUTHOR]