Inflation–forming method and time-varying performance of Tensairity domes

Tensairity domes are innovative hybrid inflatable structures that fully utilise air-induced prestress to achieve structural efficiency. However, existing research has predominantly focused on the post-inflation state, leaving the critical inflation process insufficiently explored. In this work, an efficient inflation simulation method based on control volume theory was developed. The proposed framework combines both mass flow rate (MFR) control and air pressure control to accurately simulate the deployment of inflatable structures. The method was first applied to a spindle-shaped airbag, successfully capturing its shape change during the inflation process, as demonstrated by a validation test. It was then extended to large-scale Tensairity domes. To accelerate the simulation, the computational MFR was strategically amplified. The dynamic effects resulting from this amplification were quantitatively analysed, and a decoupling strategy for adiabatic inflation and heat exchange was introduced to account for thermal effects. The results demonstrate that the proposed method can achieve precise internal pressure control, and a computational MFR below 55 kg/s is recommended for the inflation simulation. Furthermore, a symmetrical inflation sequence with multiple inflator pumps is recommended to reduce component stress during construction.