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We describe the dimensional characterization of copper quasisphere NPL-Cranfield 2. The quasisphere is assembled from two hemispheres such that the internal shape is a triaxial ellipsoid, the major axes of which have nominal radii 62.000 mm, 62.031 mm and 62.062 mm. The artefact has been manufactured using diamond-turning technology and shows a deviation from design form of less than ±1 µm over most of its surface. Our characterization involves both coordinate measuring machine (CMM) experiments and microwave resonance spectroscopy.We have sought to reduce the dimensional uncertainty below the maximum permissible error of the CMM by comparative measurements with silicon and Zerodur spheres of known volume. Using this technique we determined the equivalent radius with an uncertainty of u(k = 1) = 114 nm, a fractional uncertainty of 1.8 parts in 106. Due to anisotropy of the probe response, we could only determine the eccentricities of the quasihemispheres with a fractional uncertainty of approximately 2%.Our microwave characterization uses the TM11 to TM18 resonances. We find the equivalent radius inferred from analysis of these modes to be consistent within ±4 nm with an overall uncertainty u(k = 1) = 11 nm. We discuss corrections for surface conductivity, waveguide perturbations and dielectric surface layers.We find that the CMM radius estimates derived from each hemisphere cannot be used to accurately predict the equivalent radius of the assembled resonator for two reasons. Firstly, the equatorial flanges are flat only to within ±1 µm, leading to an equatorial ‘gap’ whose dimension cannot be reliably estimated. Secondly, the resonator undergoes significant elastic distortion when the bolts connecting the hemispheres are tightened. We provide CMM and microwave measurements to support these conclusions in addition to finite-element modelling.Finally, we consider the implications of this work on a forthcoming experiment to determine the Boltzmann constant with a relative uncertainty below 1 part in 106.

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The next generation of ground based telescopes require many hundreds of metre scale off-axis mirrors. In this paper the grinding of a 1.45 metre scale Zerodur ® mirror segment for the European Extremely Large Telescope (E-ELT) is introduced. Employing an R-theta grinding mode with a multi stage grinding process material removal rates of up to 187.5 mm 3 /s are achieved, whilst typically removing up to 1 mm depth of material in total. Results show a RMS form error of <1 µm, with subsurface damage < 10 µm, and a production cycle time of under 20 hours.

This paper provides a perspective on the development of ultra-precision technologies: What drove their evolution and what do they now promise for the future as we face the consequences of consumption of the Earth’s finite resources? Improved application of measurement is introduced as a major enabler of mass production, and its resultant impact on wealth generation is considered. This paper identifies the ambitions of the defence, automotive and microelectronics sectors as important drivers of improved manufacturing accuracy capability and ever smaller feature creation. It then describes how science fields such as astronomy have presented significant precision engineering challenges, illustrating how these fields of science have achieved unprecedented levels of accuracy, sensitivity and sheer scale. Notwithstanding their importance to science understanding, many science-driven ultra-precision technologies became key enablers for wealth generation and other well-being issues. Specific ultra-precision machine tools important to major astronomy programmes are discussed, as well as the way in which subsequently evolved machine tools made at the beginning of the twenty-first century, now provide much wider benefits.

Nanometrically-smooth infrared silicon optics can be manufactured by the diamond turning process. Due to its relatively low density, silicon is an ideal optical material for weight sensitive infrared (IR) applications. However, rapid diamond tool edge degradation and the effect on the achieved surface have prevented significant exploitation. With the aim of developing a process model to optimise the diamond turning of silicon optics, a series of experimental trials were devised using two ultra-precision diamond turning machines. Single crystal silicon specimens <1, 1, 1> were repeatedly machined using diamond tools of the same specification until the onset of surface brittle fracture. Two cutting fluids were tested. The cutting forces were monitored and the wear morphology of the tool edge was studied by scanning electron microscopy (SEM).

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