Topology optimization of a single point diamond turning fixture for a deployable primary mirror telescope

Space telescopes often face aperture size constraints due to launch vehicle dimensions, resulting in reduced apertures and compromised optical resolution. Addressing this, deployable optical payloads with segmented mirrors unfolding like petals can enhance synthetic apertures and spatial resolution. This paper compares Additive Manufacturing (AM) and Topology Optimization (TO) design in ultra-precision machining, with a focus on single-point diamond machining. The dual goal is to simultaneously reduce fixture weight and increase stiffness, countering deformations induced by rotational and cutting forces. Finite Element Analysis compares fixtures from conventional machining with those using AM and TO, shows a 68% weight reduction in TO-designed fixtures. This advancement allows a single operator to handle assembly without specialized lifting equipment, offering a promising solution to overcome space telescope limitations by significantly reducing deformation caused by forces, benefiting astronomical and Earth Observation telescope apertures.