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Proceedings Paper

Lightweighting design optimisation for additively manufactured mirrors
Author(s): 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
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Paper Abstract

Design for additive manufacture (AM; 3D printing) is significantly different than design for subtractive machining. Although there are some limitations on the designs that can be printed, the increase in the AM design-space removes some of the existing challenges faced by the traditional lightweight mirror designs; for example, sandwich mirrors are just as easy to fabricate as open-back mirrors via AM, and they provide an improvement in structural rigidity. However, the ability to print a sandwich mirror as a single component does come with extra considerations; such as orientation upon the build plate and access to remove any temporary support material. This paper describes the iterations in optimisation applied to the lightweighting of a small, 84mm diameter by 20mm height, spherical concave mirror intended for CubeSat applications. The initial design, which was fabricated, is discussed in terms of the internal lightweighting design and the design constraints that were imposed by printing and post-processing. Iterations on the initial design are presented; these include the use of topology optimisation to minimise the total internal strain energy during mirror polishing and the use of lattices combined with thickness variation i.e. having a thicker lattice in strategic support locations. To assess the suitability of each design, finite element analysis is presented to quantify the print-through of the lightweighting upon the optical surface for a given mass reduction.

Paper Details

Date Published: 9 September 2019
PDF: 19 pages
Proc. SPIE 11116, Astronomical Optics: Design, Manufacture, and Test of Space and Ground Systems II, 1111617 (9 September 2019); doi: 10.1117/12.2528105
Show Author Affiliations
Carolyn Atkins, UK Astronomy Technology Ctr. (United Kingdom)
William Brzozowski, UK Astronomy Technology Ctr. (United Kingdom)
Naomi Dobson, UK Astronomy Technology Ctr. (United Kingdom)
Maria Milanova, UK Astronomy Technology Ctr. (United Kingdom)
Stephen Todd, UK Astronomy Technology Ctr. (United Kingdom)
David Pearson, UK Astronomy Technology Ctr. (United Kingdom)
Cyril Bourgenot, Durham Univ. (United Kingdom)
David Brooks, Univ. College London (United Kingdom)
Robert Snell, The Univ. of Sheffield (United Kingdom)
Wenjuan Sun, National Physical Lab. (United Kingdom)
Peter Cooper, National Physical Lab. (United Kingdom)
Simon G. Alcock, Diamond Light Source Ltd. (United Kingdom)
Ioana-Theodora Nistea, Diamond Light Source Ltd. (United Kingdom)

Published in SPIE Proceedings Vol. 11116:
Astronomical Optics: Design, Manufacture, and Test of Space and Ground Systems II
Tony B. Hull; Dae Wook Kim; Pascal Hallibert, Editor(s)

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