Flex-16: A large-displacement monolithic compliant rotational hinge

•We introduce a monolithic rotational hinge capable of 90 degrees of rotation.•Parametric finite element analysis was used to perform a configuration study.•Five prototypes were fabricated and tested.•They are demonstrated in polypropylene, titanium and carbon nanotube framework.

This paper introduces a large-displacement monolithic compliant rotational hinge, called the Flex-16. The Flex-16 achieves 90° of rotation and is aimed for application as a compliant deployment hinge. A nonlinear parametric finite element model was created to rapidly analyze a variety of designs identified during a configuration study. Prototypes were tested to verify the model and to validate that the Flex-16 was capable of 90° of rotation without failure or self collision. Five prototypes were fabricated from three different materials (polypropylene, titanium, and a carbon nanotube framework) on two different size scales (macro and micro). Rotational stiffness, stress, center shift, and mode shapes and frequencies were analyzed.