Metal mirrors are used for spaceborne optical systems, such as telescopes and spectrometers. In addition to the optical performance, the mechanical needs and the mass restrictions are important aspects during the design and manufacturing process. Using the additive manufacturing process, optimized internal lightweight structures are realized to reduce the weight of the system while keeping the mechanical stability. A mass reduction of ≈60.5% is achieved. Using the aluminum silicon alloy AlSi40, the thermal mismatch of the mirror base body to a necessary electroless nickel-polishing layer is minimized. Based on an exemplary mirror design, the optimization of the interior lightweight structure is described, followed by the manufacturing process from additive manufacturing to diamond turning, plating, and polishing. Finally, the results of surface metrology and light scattering measurements are presented. A final form deviation below 80 nm p: − v: and a roughness of ∼1 nm rms could be demonstrated.
The design of an optical housing for laser telecommunication in space is improved by topology optimization. Different mechanical and thermal boundary conditions are considered while minimizing the overall weight of the housing. As a proof-of-concept study, a complex and lightweight housing is made by additive manufacturing with the aluminium silicon alloy AlSi40. Post processing steps include a thermal treatment, cleaning and a mechanical machining process. Final characterization tests include the evaluation of material characteristics by tensile tests, a computed tomography scan and a CMM measurement. The final shock and vibrational test is used to proof the performance of the housing for future space applications.
Varying temperatures influence the figure errors of freeform metal mirrors by thermal expansion. Furthermore, different materials lead to thermo-elastic bending effects. The paper presents a derivation of a compensation approach for general static loads. Utilizing perturbation theory, this approach works for shape compensation of substrates that operate in various temperature environments. Verification is made using a finite element analysis, which is further used to produce manufacturable CAD models. The remaining low spatial frequency errors are deterministically correctable using diamond turning or polishing techniques.
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