Foldable nested frame solar array system and method of manufacture

1 . A system comprising:

N populated frame assemblies (PFAs) having a folded nested state and an unfolded state, wherein the N PFAs are deployable from the folded nested state to the unfolded state and the N PFAs have a nesting stack height when in the folded nested state that is less than a sum of the individual height of all PFAs of the N PFAs, where the N is a non-zero integer number greater than one, wherein each PFA comprises a frame that comprises nestable frame (NF) members on first parallel and opposing sides of the frame, wherein each NF member comprises a top surface with a longitudinal length and a first longitudinal wall and a second longitudinal wall, wherein the first and second longitudinal walls are opposing, wherein each NF member further comprises at least one channel configured to nest a respective NF member of an adjacent PFA within the at least one channel, wherein the at least one channel is formed from an underside of the top surface and between interior surfaces of the first and second longitudinal walls of each NF member.

2 . The system of claim 1 , further comprising a satellite or spacecraft having the N PFAs affixed to the satellite or spacecraft.

3 . The system of claim 1 , wherein each PFA further includes:

traverse frame members perpendicular to the NF members,

wherein the frame is one of a monolithic structure and a modular structure.

4 . The system of claim 1 , wherein the N PFAs include:

first PFAs configured to deploy in series, the first PFAs includes a support PFA; and

second PFAs affixed to the support PFA, the second PFAs deploy from the support PFA in a parallel.

5 . The system of claim 1 , wherein each PFA further includes:

traverse frame members on second parallel and opposing sides of the frame that are perpendicular to the NF members; and

insertable extension frame sections to expand the frame along at least one dimension.

6 . The system of claim 1 , wherein each PFA includes:

subframes that include self-aligning, nestable frame (NF) members on first parallel and opposing sides of the subframe and traverse frame members perpendicular to the NF members,

wherein the subframes share a respective NF member of the NF members.

7 . The system of claim 1 , wherein each PFA is coupled to an adjacent PFA by an unfolding mechanism that produces a motive force.

8 . The system of claim 1 , wherein the frame of each PFA includes a frame profile with the at least one channel; and frames of adjacent PFAs are connected so that the at least one channel of the frame profiles are opposing.

9 . The system of claim 1 , wherein each PFA further includes:

a seat between the NF members;

a recess in a center of the frame configured to allow a next frame of a next PFA to nest in the recess when stacked; and

a membrane coupled to the seat of the frame;

wherein the NF members are self-aligning.

10 . The system of claim 9 , wherein each PFA further includes a payload affixed to the membrane.

11 . The system of claim 9 , wherein:

each NF member includes a hollow structure with a top side and an open base and a height between the top side and the open base;

the hollow structure including the at least one channel formed in the hollow structure; and

the open base has a width that is larger than a width of the top side.

12 . The system of claim 9 , wherein each NF member is comprised of a two-dimensional constant cross-section.

13 . The system of claim 9 , wherein each NF member does not have a constant cross-section but is still comprised of a three-dimensional shape containing at least one recess configured to nest a respective NF member of an adjacent PFA within,

wherein the three-dimensional shape may or may not be comprised of a repeating pattern of regions.