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Fabrication Strategy of Additively Manufactured Metal Mirror Based on Multi-Load Topology Optimization and
Qianglong Wang1,2, Chong Wang1, Yisheng Chen1,2
1Changchun Institute of Optics, Fine Mechanics and Physics (CIOMP), Chinese Academy of Sciences, Changchun, China.
3D Printing and Additive Manufacturing
|January 1, 2025
Summary
This study details a fabrication strategy for metal mirrors using topology optimization and additive manufacturing. The optimized design suppresses vibrations during diamond turning, enabling direct application in infrared optical systems.
Area of Science:
- Materials Science and Engineering
- Optical Engineering
- Manufacturing Technology
Background:
- Metal mirrors are crucial components in optical systems.
- Traditional fabrication methods can be limited in design complexity and efficiency.
- Additive manufacturing offers new possibilities for complex mirror structures.
Purpose of the Study:
- To present a comprehensive fabrication strategy for metal mirrors.
- To optimize the structural design of a 200mm diameter metal mirror for additive manufacturing and surface processing.
- To validate the applicability of the fabricated mirrors in infrared optical systems.
Main Methods:
- Topology optimization model development considering multi-load conditions and additive manufacturing constraints.
- Additive manufacturing of an aluminum-based alloy (AlSi10Mg) mirror.
- High-precision single-point diamond turning for surface finishing.
- Optical interferometer for surface inspection.
Main Results:
- Successful topology design and additive manufacturing of a 200mm metal mirror.
- The optimization model effectively reduced vibration during single-point diamond turning.
- Achieved high-precision surface quality suitable for optical applications.
Conclusions:
- The proposed fabrication strategy is effective for producing high-performance metal mirrors.
- The optimized design and manufacturing process are suitable for infrared reflective imaging optical systems.
- Additive manufacturing combined with advanced optimization presents a viable route for next-generation optical components.
