National Technical Reports Library

The National Technical Information Service acquires, indexes, abstracts, and archives the largest collection of U.S. government-sponsored technical reports in existence. The NTRL offers online, free and open access to these authenticated government technical reports. Technical reports and documents in its repository may be available online for free either from the issuing federal agency, the U.S. Government Publishing Office’s Federal Digital System website, or through search engines.

Details

Novel Method for Fabricating Additive Manufactured Lightweight, Optical Quality Metallic Mirrors.

AD1033942

Publication Date	2016
Personal Author	Stern, M. L.; Bari, J. M.
Page Count	13
Abstract	Lightweight optics have been a focus for airborne and space borne applications in which the size, weight, and power (SWaP) of the system are critical. Many different methods for fabricating lowweight optics are in use today. We present a novel methodology for generating lightweight metallic mirrors fabricated by growing an additive manufactured blank, post processing the faces, coating with electroless nickel, and diamond turning. Test coupons were characterized and compared against performance specifications. The process was then used in a case study of the development of a lowweight spinning mirror, in which topology optimization was used. The blank was then fabricated with metallic powder bed fusion and post processed to deliver optical quality mirror surfaces. Through this case study the flexibility of this novel post processing method is demonstrated; enabling complex metal additive manufactured blanks to be processed into high quality mirrors greatly expanding the design space. This technology has the opportunity to reduce cost and increase the performance in many optical applications.
Keywords	Lightweight Optics Airborne Spaceborne Methodology Fabrication Systems engineering Spacecraft Aircraft Additive manufacturing Mirrors Size Weight And power Metallic mirrors
Source Agency	Non Paid ADAS
NTIS Subject Category	41G - Quality Control & Reliability
Corporate Authors	Massachusetts Inst. of Tech., Lexington. Lincoln Lab.
Supplemental Notes	Rapid Prototyping Journal , 01 Jan 0001, 01 Jan 0001,
Document Type	Technical Report
Title Note	Technical Report
NTIS Issue Number	201807
Contract Number	FA872105C0002

Novel Method for Fabricating Additive Manufactured Lightweight, Optical Quality Metallic Mirrors.

Novel Method for Fabricating Additive Manufactured Lightweight, Optical Quality Metallic Mirrors.
AD1033942

Publication Date	2016
Personal Author	Stern, M. L.; Bari, J. M.
Page Count	13
Abstract	Lightweight optics have been a focus for airborne and space borne applications in which the size, weight, and power (SWaP) of the system are critical. Many different methods for fabricating lowweight optics are in use today. We present a novel methodology for generating lightweight metallic mirrors fabricated by growing an additive manufactured blank, post processing the faces, coating with electroless nickel, and diamond turning. Test coupons were characterized and compared against performance specifications. The process was then used in a case study of the development of a lowweight spinning mirror, in which topology optimization was used. The blank was then fabricated with metallic powder bed fusion and post processed to deliver optical quality mirror surfaces. Through this case study the flexibility of this novel post processing method is demonstrated; enabling complex metal additive manufactured blanks to be processed into high quality mirrors greatly expanding the design space. This technology has the opportunity to reduce cost and increase the performance in many optical applications.
Keywords	Lightweight Optics Airborne Spaceborne Methodology Fabrication Systems engineering Spacecraft Aircraft Additive manufacturing Mirrors Size Weight And power Metallic mirrors
Source Agency	Non Paid ADAS
NTIS Subject Category	41G - Quality Control & Reliability
Corporate Authors	Massachusetts Inst. of Tech., Lexington. Lincoln Lab.
Supplemental Notes	Rapid Prototyping Journal , 01 Jan 0001, 01 Jan 0001,
Document Type	Technical Report
Title Note	Technical Report
NTIS Issue Number	201807
Contract Number	FA872105C0002