I think the video below shows folding a ~16 sq ft (5 sq m) septagon into roughly a 2.3 ft x 1.7 ft cylinder. Unsure of material thickness... perhaps 1/4 inch. So not clear how well it would work with 1-inch-thick R-MAX foam insulation.
- Video demonstration (starts a 1:52)
- More details at www.salazarigami.com/starshade (page archive)
- ORIPA: origami pattern simulator & source code
- septagon starshade SVG pattern
The summer of 2015, I began working on the Starshade project to design an origami crease pattern that would allow a 20m diameter conical optical shield to deploy from a small well defined volume in space while creating a perfect light seal with the mechanical truss that deploys it. The optical shield has a 28-sided perimeter and is made of a compressible laminar composite of kapton, foam, and kapton that is collectively 1.6cm thick. When stowed, the optical shield should wrap around a 1.6m diameter hub while not exceeding 2.8m in diameter or 1.95m in height."