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A new concept investigated in the laboratory eliminates the disadvantages previously associated with structures capable of rigidization after expansion, and yields structures of far greater strengths than conventional expandable structures of comparable weight. This concept appears applicable to both unmanned and manned flights. The technique utilizes gaseous catalysts which expand the structure and convert viscous liquid prepolymer impregnants to tough rigid materials. Data are presented for the mechanisms of the concept and mechanical properties of the materials before and after rigidization.