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Proceedings Paper

Optical fabrication of lightweighted 3D printed mirrors
Author(s): Harrison Herzog; Jacob Segal; Jeremy Smith; Richard Bates; Jacob Calis; Alyssa De La Torre; Dae Wook Kim; Joni Mici; Jorge Mireles; David M. Stubbs; Ryan Wicker
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Paper Abstract

Direct Metal Laser Sintering (DMLS) and Electron Beam Melting (EBM) 3D printing technologies were utilized to create lightweight, optical grade mirrors out of AlSi10Mg aluminum and Ti6Al4V titanium alloys at the University of Arizona in Tucson. The mirror prototypes were polished to meet the λ/20 RMS and λ/4 P-V surface figure requirements. The intent of this project was to design topologically optimized mirrors that had a high specific stiffness and low surface displacement. Two models were designed using Altair Inspire software, and the mirrors had to endure the polishing process with the necessary stiffness to eliminate print-through. Mitigating porosity of the 3D printed mirror blanks was a challenge in the face of reconciling new printing technologies with traditional optical polishing methods. The prototypes underwent Hot Isostatic Press (HIP) and heat treatment to improve density, eliminate porosity, and relieve internal stresses. Metal 3D printing allows for nearly unlimited topological constraints on design and virtually eliminates the need for a machine shop when creating an optical quality mirror. This research can lead to an increase in mirror mounting support complexity in the manufacturing of lightweight mirrors and improve overall process efficiency. The project aspired to have many future applications of light weighted 3D printed mirrors, such as spaceflight. This paper covers the design/fab/polish/test of 3D printed mirrors, thermal/structural finite element analysis, and results.

Paper Details

Date Published: 2 September 2015
PDF: 15 pages
Proc. SPIE 9573, Optomechanical Engineering 2015, 957308 (2 September 2015); doi: 10.1117/12.2188197
Show Author Affiliations
Harrison Herzog, The Univ. of Arizona (United States)
Jacob Segal, The Univ. of Arizona (United States)
Jeremy Smith, The Univ. of Arizona (United States)
Richard Bates, The Univ. of Arizona (United States)
Jacob Calis, The Univ. of Arizona (United States)
Alyssa De La Torre, The Univ. of Arizona (United States)
Dae Wook Kim, The Univ. of Arizona (United States)
Joni Mici, Lockheed Martin Space Systems Advanced Technology Ctr. (United States)
Jorge Mireles, The Univ. of Texas at El Paso (United States)
David M. Stubbs, Lockheed Martin Space Systems Advanced Technology Ctr. (United States)
Ryan Wicker, The Univ. of Texas at El Paso (United States)

Published in SPIE Proceedings Vol. 9573:
Optomechanical Engineering 2015
Alson E. Hatheway, Editor(s)

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