Additively manufactured mirrors for CubeSats

Carolyn Atkins; William Brzozowski; Naomi Dobson; Maria Milanova; Stephen Todd; David Pearson; Cyril Bourgenot; David Brooks; Robert Snell; Wenjuan Sun; Peter Cooper; Simon G Alcock; Ioana-Theodora Nistea

doi:10.1117/12.2528119

16 September 2019 Additively manufactured mirrors for CubeSats

Carolyn Atkins, William Brzozowski, Naomi Dobson, Maria Milanova, Stephen Todd, David Pearson, Cyril Bourgenot, David Brooks, Robert Snell, Wenjuan Sun, Peter Cooper, Simon G Alcock, Ioana-Theodora Nistea

Author Affiliations +

Proceedings Volume 11116, Astronomical Optics: Design, Manufacture, and Test of Space and Ground Systems II; 1111616 (2019) https://doi.org/10.1117/12.2528119
Event: SPIE Optical Engineering + Applications, 2019, San Diego, California, United States

Abstract

Additive manufacturing (AM; 3D printing) is a fabrication process that builds an object layer-upon-layer and promotes the use of structures that would not be possible via subtractive machining. Prototype AM metal mirrors are increasingly being studied in order to exploit the advantage of the broad AM design-space to develop intricate lightweight structures that are more optimised for function than traditional open-back mirror lightweighting. This paper describes a UK Space Agency funded project to design and manufacture a series of lightweighted AM mirrors to fit within a 3U CubeSat chassis. Six AM mirrors of identical design will be presented: two in aluminium (AlSi₁₀Mg), two in nickel phosphorous (NiP) coated AlSi₁₀Mg, and two in titanium (Ti64). For each material mirror pair, one is hand-polished and the other is diamond turned. Metrology data, surface form error and surface roughness, will be presented to compare and contrast the different materials and post-processing methods. To assess the presence of porosity, a frequent concern for AM materials, X-ray computed tomography measurements will be presented to highlight the location and density of pores within the mirror substrates; methods to mitigate the distribution of pores near the optical surface will be described. As a metric for success the AlSi₁₀Mg + NiP and AlSi₁₀Mg mirrors should be suitable for visible and infrared applications respectively.

Conference Presentation

Citation Download Citation

Carolyn Atkins, William Brzozowski, Naomi Dobson, Maria Milanova, Stephen Todd, David Pearson, Cyril Bourgenot, David Brooks, Robert Snell, Wenjuan Sun, Peter Cooper, Simon G Alcock, and Ioana-Theodora Nistea "Additively manufactured mirrors for CubeSats", Proc. SPIE 11116, Astronomical Optics: Design, Manufacture, and Test of Space and Ground Systems II, 1111616 (16 September 2019); https://doi.org/10.1117/12.2528119

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