Optical fabrication of lightweighted 3D printed mirrors

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

doi:10.1117/12.2188197

Optical fabrication of lightweighted 3D printed mirrors

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

Optical Sciences

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution

32 Scopus citations

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 lightweighted 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.

Original language	English (US)
Title of host publication	Optomechanical Engineering 2015
Editors	Alson E. Hatheway
Publisher	SPIE
ISBN (Electronic)	9781628417395
DOIs	https://doi.org/10.1117/12.2188197
State	Published - 2015
Event	Optomechanical Engineering 2015 - San Diego, United States Duration: Aug 10 2015 → Aug 12 2015

Publication series

Name	Proceedings of SPIE - The International Society for Optical Engineering
Volume	9573
ISSN (Print)	0277-786X
ISSN (Electronic)	1996-756X

Conference

Conference	Optomechanical Engineering 2015
Country/Territory	United States
City	San Diego
Period	8/10/15 → 8/12/15

Keywords

Additive manufacturing
DMLS
EBM
Lightweight
Mirror
Polish
Topological optimization

ASJC Scopus subject areas

Electronic, Optical and Magnetic Materials
Condensed Matter Physics
Computer Science Applications
Applied Mathematics
Electrical and Electronic Engineering

Access to Document

10.1117/12.2188197

Cite this

Herzog, H., Segal, J., Smith, J., Bates, R., Calis, J., De La Torre, A., Kim, D. W., Mici, J., Mireles, J., Stubbs, D. M., & Wicker, R. (2015). Optical fabrication of lightweighted 3D printed mirrors. In A. E. Hatheway (Ed.), Optomechanical Engineering 2015 Article 957308 (Proceedings of SPIE - The International Society for Optical Engineering; Vol. 9573). SPIE. https://doi.org/10.1117/12.2188197

Herzog, H, Segal, J, Smith, J, Bates, R, Calis, J, De La Torre, A, Kim, DW, Mici, J, Mireles, J, Stubbs, DM & Wicker, R 2015, Optical fabrication of lightweighted 3D printed mirrors. in AE Hatheway (ed.), Optomechanical Engineering 2015., 957308, Proceedings of SPIE - The International Society for Optical Engineering, vol. 9573, SPIE, Optomechanical Engineering 2015, San Diego, United States, 8/10/15. https://doi.org/10.1117/12.2188197

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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 lightweighted 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.",

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AB - 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 lightweighted 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.

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Optical fabrication of lightweighted 3D printed mirrors

Abstract

Publication series

Conference

Keywords

ASJC Scopus subject areas

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