Lightweight and High-Stiffness Metal Optical Systems Based on Additive Manufacturing

Area of Science:

• Optical Engineering
• Aerospace Engineering
• Materials Science

Background:

• Deep space exploration requires advanced optical systems for low-temperature target detection.
• Existing systems often face challenges with weight and field of view limitations.
• Developing lightweight, wide field-of-view systems is crucial for enhancing observational capabilities.

Purpose of the Study:

• To design and fabricate a long-wave infrared catadioptric optical system for deep space applications.
• To achieve a lightweight and wide field-of-view optical system through innovative design and manufacturing techniques.
• To validate the system's performance against diffraction-limited standards.

Main Methods:

• Design of a compact catadioptric optical system with local cooling (55 mm aperture, 110 mm focal length, 4°x4° FOV).
• Application of topology optimization for designing mirror assemblies and baffle, achieving 1213.7 Hz resonance frequency.
• Additive manufacturing (3D printing) and single-point diamond turning for mirror fabrication, followed by centering assembly.

Main Results:

• The optical system achieved diffraction-limited modulation transfer function (MTF) across the entire field of view.
• Significant weight reduction achieved, with the final system weighing only 96.04 g.
• Successful integration of local cooling, topology optimization, and additive manufacturing.

Conclusions:

• Additive manufacturing is an effective method for enhancing optical system performance, particularly for space applications.
• The developed system meets the demanding requirements for deep space low-temperature target detection.
• The combination of advanced design and manufacturing techniques offers a viable path for future lightweight, high-performance optical systems.