Understanding the role of additive manufacturing in the development of astronomical hardware

Carolyn Atkins; Younes Chahid; James T. Wells; Marcell Westsik; Katherine Morris; Ciarán Breen; Alastair Macleod; Lawrence Bissell; William Cochrane; Richard Kotlewski; Scott McPhee; Robert M. Snell; Iain Todd; Mat Beardsley; Michael Harris; Misael Pimentel; Scott McKegney; Jonathan Orr; Simon G. Alcock; Ioana Theodora Nistea; Simone Cottarelli; Samuel Tammas-Williams

doi:10.1117/12.2677452

4 October 2023 Understanding the role of additive manufacturing in the development of astronomical hardware

Carolyn Atkins, Younes Chahid, James T. Wells, Marcell Westsik, Katherine Morris, Ciarán Breen, Alastair Macleod, Lawrence Bissell, William Cochrane, Richard Kotlewski, Scott McPhee, Robert M. Snell, Iain Todd, Mat Beardsley, Michael Harris, Misael Pimentel, Scott McKegney, Jonathan Orr, Simon G. Alcock, Ioana Theodora Nistea, Simone Cottarelli, Samuel Tammas-Williams

Author Affiliations +

Proceedings Volume 12677, Astronomical Optics: Design, Manufacture, and Test of Space and Ground Systems IV; 126770L (2023) https://doi.org/10.1117/12.2677452
Event: SPIE Optical Engineering + Applications, 2023, San Diego, California, United States

Abstract

Lightweight optical manufacture is no longer confined to the conventional subtractive (mill and drill), formative (casting and forging) and fabricative (bonding and fixing) manufacturing methods. Additive manufacturing (AM; 3D printing), creating a part layer-by-layer, provides new opportunities to reduce mass and combine multiple parts into one structure. Frequently, modern astronomical telescopes and instruments, ground- and space-based, are limited in mass and volume, and are complex to assemble, which are limitations that can benefit from AM. However, there are challenges to overcome before AM is considered a conventional method of manufacture, for example, upskilling engineers, increasing the technology readiness level via AM case studies, and understanding the AM build process to deliver the required material properties. This paper describes current progress within a four-year research programme that has the goal to explore these challenges towards creating a strategy for AM adoption within astronomical hardware. Working with early-career engineers, case studies have been undertaken which focus on lightweight AM aluminium mirror manufacture and optical mountings. In parallel, the aluminium AM build parameters have been investigated to understand which combination of parameters results in AM parts with consistent material properties and low defects. Metrology results from two AM case studies will be summarised: the optical characteristics of a lightweighted aluminium mirror intended for in-orbit deployment from a nanosat; and the AM build quality of wire arc additive manufacture for use in an optomechanical housing. Finally, an analysis of how surface roughness from AM mirror samples and build parameters are linked will be discussed.

Conference Presentation

(2023) Published by SPIE. Downloading of the abstract is permitted for personal use only.

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Carolyn Atkins, Younes Chahid, James T. Wells, Marcell Westsik, Katherine Morris, Ciarán Breen, Alastair Macleod, Lawrence Bissell, William Cochrane, Richard Kotlewski, Scott McPhee, Robert M. Snell, Iain Todd, Mat Beardsley, Michael Harris, Misael Pimentel, Scott McKegney, Jonathan Orr, Simon G. Alcock, Ioana Theodora Nistea, Simone Cottarelli, and Samuel Tammas-Williams "Understanding the role of additive manufacturing in the development of astronomical hardware", Proc. SPIE 12677, Astronomical Optics: Design, Manufacture, and Test of Space and Ground Systems IV, 126770L (4 October 2023); https://doi.org/10.1117/12.2677452

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