Jove
Visualize
Contact Us

Related Concept Videos

JoVE
x logofacebook logolinkedin logoyoutube logo
ABOUT JoVE
OverviewLeadershipBlogJoVE Help Center
AUTHORS
Publishing ProcessEditorial BoardScope & PoliciesPeer ReviewFAQSubmit
LIBRARIANS
TestimonialsSubscriptionsAccessResourcesLibrary Advisory BoardFAQ
RESEARCH
JoVE JournalMethods CollectionsJoVE Encyclopedia of ExperimentsArchive
EDUCATION
JoVE CoreJoVE BusinessJoVE Science EducationJoVE Lab ManualFaculty Resource CenterFaculty Site
Terms & Conditions of Use
Privacy Policy
Policies
  1. Home
  3. On-machine Measurement And Zernike-based Compensation Cutting For Large-aperture Additive Metal Mirrors With Ultra-high Lightweight Ratio.
  1. Home
  3. On-machine Measurement And Zernike-based Compensation Cutting For Large-aperture Additive Metal Mirrors With Ultra-high Lightweight Ratio.

Related Experiment Video

Automated Delivery of Microfabricated Targets for Intense Laser Irradiation Experiments
06:40

Automated Delivery of Microfabricated Targets for Intense Laser Irradiation Experiments

Published on: January 28, 2021

4.7K

On-machine measurement and Zernike-based compensation cutting for large-aperture additive metal mirrors with

Chen Wang, Kai Xu, Xiao Sun

    Optics Express
    |September 23, 2025

    View abstract on PubMed

    Summary
    This summary is machine-generated.

    This study presents an advanced on-machine measurement and compensation cutting method for large-aperture additively-manufactured metal mirrors. The novel approach significantly reduces surface errors, improving precision machining efficiency.

    More Related Videos

    In Situ Measurement of Vacuum Window Birefringence using 25Mg+ Fluorescence
    07:03

    In Situ Measurement of Vacuum Window Birefringence using 25Mg+ Fluorescence

    Published on: June 13, 2020

    4.2K
    The Generation of Higher-order Laguerre-Gauss Optical Beams for High-precision Interferometry
    12:14

    The Generation of Higher-order Laguerre-Gauss Optical Beams for High-precision Interferometry

    Published on: August 12, 2013

    22.4K

    Related Experiment Videos

    Automated Delivery of Microfabricated Targets for Intense Laser Irradiation Experiments
    06:40

    Automated Delivery of Microfabricated Targets for Intense Laser Irradiation Experiments

    Published on: January 28, 2021

    4.7K
    In Situ Measurement of Vacuum Window Birefringence using 25Mg+ Fluorescence
    07:03

    In Situ Measurement of Vacuum Window Birefringence using 25Mg+ Fluorescence

    Published on: June 13, 2020

    4.2K
    The Generation of Higher-order Laguerre-Gauss Optical Beams for High-precision Interferometry
    12:14

    The Generation of Higher-order Laguerre-Gauss Optical Beams for High-precision Interferometry

    Published on: August 12, 2013

    22.4K

    Area of Science:

    • Optics and Materials Science
    • Additive Manufacturing
    • Precision Engineering

    Background:

    • Large-aperture additively-manufactured metal mirrors are crucial for optics, astronomy, and aerospace.
    • Precision diamond cutting of these mirrors is challenging due to non-uniform lightweight structures.
    • Current on-machine measurement and compensation cutting techniques are immature and hindered by error coupling.

    Purpose of the Study:

    • To develop an advanced on-machine measurement system and compensation cutting method for additively-manufactured metal mirrors.
    • To address challenges in precision machining of large-aperture, lightweight metal mirrors.
    • To improve the precision and efficiency of ultra-precision machining.

    Main Methods:

    • Developed an on-machine measurement system integrated with Zernike polynomial-based compensation cutting.
  • Extracted the first 36 Zernike terms for surface error compensation.
  • Fabricated a 510 mm diameter, 86% lightweight ratio AlSi10Mg additively-manufactured mirror.

    • Main Results:

    • Achieved 50 nm root-mean-square (RMS) repeatability with the on-machine measurement system.
    • Validated the system's reliability against coordinate measuring machine results.
    • Reduced surface error from 0.636 μm to 0.30 μm RMS (52% convergence) after one compensation cutting cycle.

    Conclusions:

    • The proposed on-machine measurement and Zernike polynomial compensation cutting method significantly enhances precision machining of additively-manufactured metal mirrors.
    • The study demonstrates a novel approach for fabricating large-diameter, high-lightweight ratio mirrors.
    • This methodology offers a promising solution for improving both the precision and efficiency of ultra-precision machining.