Additive manufacturing (AM; 3D printing) in aluminium using laser powder bed fusion provides a new design space for lightweight mirror production. Printing layer-by-layer enables the use of intricate lattices for mass reduction, as well as organic shapes generated by topology optimisation, resulting in mirrors optimised for function as opposed to subtractive machining. However, porosity, a common AM defect, is present in printed aluminium and it is a result of the printing environment being either too hot or too cold, or gas entrapped bubbles within the aluminium powder. When present in an AM mirror substrates, porosity manifests as pits on the reflective surface, which increases micro-roughness and therefore scattered light. There are different strategies to reduce the impact of porosity: elimination during printing, coating the aluminium print in nickel phosphorous, or to apply a heat and pressure treatment to close the pores, commonly known as a hot isostatic press (HIP).
This paper explores the application of HIP on printed aluminium substrates intended for mirror production using single point diamond turning (SPDT). The objective of the HIP is to reduce porosity whilst targeting a small grain growth within the aluminium, which is important in allowing the SPDT to generate surfaces with low micro-roughness. For this study, three disks, 50 mm diameter by 5 mm, were printed in AlSi10Mg at 0◦, 45◦, and 90◦ with respect to the build plate. X-ray computed tomography (XCT) was conducted before and after the HIP cycle to confirm the effectiveness of HIP to close porosity. The disks were SPDT and the micro-roughness evaluated. Mechanical testing and electron backscatter diffraction (EBSD) was used to quantify the mechanical strength and the grain size after HIP.
Lightweight optical manufacture is no longer confined to the conventional subtractive (mill and drill), formative (casting and forging) and fabricative (bonding and fixing) manufacturing methods. Additive manufacturing (AM; 3D printing), creating a part layer-by-layer, provides new opportunities to reduce mass and combine multiple parts into one structure. Frequently, modern astronomical telescopes and instruments, ground- and space-based, are limited in mass and volume, and are complex to assemble, which are limitations that can benefit from AM. However, there are challenges to overcome before AM is considered a conventional method of manufacture, for example, upskilling engineers, increasing the technology readiness level via AM case studies, and understanding the AM build process to deliver the required material properties. This paper describes current progress within a four-year research programme that has the goal to explore these challenges towards creating a strategy for AM adoption within astronomical hardware. Working with early-career engineers, case studies have been undertaken which focus on lightweight AM aluminium mirror manufacture and optical mountings. In parallel, the aluminium AM build parameters have been investigated to understand which combination of parameters results in AM parts with consistent material properties and low defects. Metrology results from two AM case studies will be summarised: the optical characteristics of a lightweighted aluminium mirror intended for in-orbit deployment from a nanosat; and the AM build quality of wire arc additive manufacture for use in an optomechanical housing. Finally, an analysis of how surface roughness from AM mirror samples and build parameters are linked will be discussed.
Fabricating mirrors using additive manufacturing (AM; 3D printing) is a promising yet under-researched production route. There are several issues that need to be better understood before AM can be fully adopted to fabricate mirror substrates. A significant obstacle to AM adoption is the presence of porosity and the influence that has on the resultant optical proprieties. Several batches of high-silicon aluminium (AlSi10Mg) samples were created to investigate the relationships laser parameters, laser paths and build orientations have with the porosity. The results showed that eliminating defects relies on a complex interaction of the process parameters and material properties, with the residual heating from the laser proving to be a significant factor. In addition, the use of a hot isostatic press is investigated and some full prototypes of the Cassegrain CubeSat were produced.
Additive manufacture (AM), also known as 3D printing, builds an object, layer-by-layer, from a digital design file. The primary advantage of the layer-by-layer approach is the increase in design-space, which enables engineers and scientists to create structures and geometries that would not be practical, or possible, via conventional subtractive machining (mill, drill and lathe). AM provides more than prototyping solutions: there are a broad range of materials available (polymers, metals and ceramics); software capable of creating lightweight structures optimised for the physical environment; and numerous bureaux offering AM as a service on a par with subtractive machining. In addition, AM is an ideal method for bespoke, low-count parts, which are often the foundation of astronomical instrumentation. However, AM offers many challenges as well as benefits and, therefore, the goal of the OPTICON A2IM Cookbook is to provide the reader with a resource that outlines the scope of AM and how to adopt it within astronomical hardware, with an emphasis on the fabrication of lightweight mirrors. The Cookbook was an open access deliverable of the EU H2020 funded OPTICON (Optical Infrared Coordination Network for Astronomy; grant agreement #730890) A2IM (Additive Astronomy Integrated-component Manufacturing; PI H. Schnetler) work package and it was completed in June 2021. This paper will introduce the Cookbook, its scope and methodology, and highlight the paradigm shift required to design and AM lightweight mirrors for astronomy and space-science.
Lightweight, aluminum, freeform prototype mirrors have been designed and fabricated by a Thai led team, with UK support, for intended applications within the Thai Space Consortium (TSC) satellite series. The project motivation was to explore the different design strategies and fabrication steps enabled by both conventional (mill, drill, and lathe) and additive (3D printing) manufacture of the prototype substrates. Single Point Diamond Turning was used to convert the substrates into mirrors and optical metrology was used to evaluate the different mirror surfaces. The prototype criteria originated from the TSC-1 satellite tertiary mirror, which is designed to minimize the effect of Seidel aberrations before the beam enters the hyperspectral imager. To converge upon the prototype designs, Finite Element Analysis (FEA) was used to evaluate the different physical conditions experienced by the prototypes during manufacture and how these influence the optical performance. The selected designs satisfied the mass and surface displacement criteria of the prototype and were adapted to either the conventional or additive manufacturing process. This paper will present the prototype design process, substrate manufacture, optical fabrication, and an interferometric evaluation of the optical surfaces comparing the conventional and additive manufacturing processes.
Additive Manufacturing (AM; 3D printing) for mirror fabrication allows for intricate designs that can combine lightweight structures and integrated mounting. Conventional lightweight structures utilise cubic or prismatic unit cells, which do not provide uniform support at the edge of curved mirrors. We present a new circular lattice based upon cylindrical coordinates and how this lattice has been incorporated within an 80 mm diameter mirror intended for use in a 3U CubeSat telescope. Several design iterations are explored, which include prototype mirrors produced in a titanium alloy and a finite element analysis of the one of the design iterations.
In this paper we are exploring the possibilities of 3D printing in the fabrication of mirrors for astronomy. Taking the advantages of 3D printing to solve the existing problems caused by traditional manufacturing, two proof-of- concept mirror fabrication strategies are investigated in this paper. The first concept is a deformable mirror with embedded actuator supports system to minimise errors caused by the bonding interfaces during mirror assembly. The second concept is the adaption of the Stress Mirror Polishing (SMP) technique to a variety of mirror shapes by implemented a printed thickness distribution on the back side of the mirror. Design investigations and prototypes plans are presented for both studies.
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