Composite mirror replication: curing, coating and polishing

Jack J. Massarello; Jake D. Hochhalter; Paul A. Fuierer; Arup K. Maji

doi:10.1117/12.614603

18 August 2005 Composite mirror replication: curing, coating and polishing

Jack J. Massarello, Jake D. Hochhalter, Paul A. Fuierer, Arup K. Maji

Proceedings Volume 5868, Optical Materials and Structures Technologies II; 58680O (2005) https://doi.org/10.1117/12.614603
Event: Optics and Photonics 2005, 2005, San Diego, California, United States

Abstract

The quickest method for generating a lightweight composite optic is to replicate an optical quality glass tool onto a carbon fiber reinforced polymer (CFRP). However, the effects of fiber print-through create an unacceptable surface roughness on replicated CFRP mirrors. In order to mitigate fiber print-through, two methods of generating a polishable resin layer were investigated. The first method employs the application of resin films to the CFRP surface. The second, unconventional method generates a co-cured resin layer using a magnetic fiber migration approach. A final polishing step was used to attain optical quality surface features on all of the replicated specimens. Replicated resin films with thicknesses ≥ 0.25 mm sufficiently mitigate fiber print-through. Room temperature and high temperature cure resins were polished below 50 Å rms surface roughness (1 μm to 1mm bandwidth) or better. The magnetic fiber migration technique was suitable for eliminating fiber print-through. Replicated magnetic fiber laminates were polished to within specular quality as well.

Citation Download Citation

Jack J. Massarello, Jake D. Hochhalter, Paul A. Fuierer, and Arup K. Maji "Composite mirror replication: curing, coating and polishing", Proc. SPIE 5868, Optical Materials and Structures Technologies II, 58680O (18 August 2005); https://doi.org/10.1117/12.614603

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