Optical fabrication of lightweighted 3D printed mirrors
Optical fabrication of lightweighted 3D printed mirrors
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轻量化 3D 打印镜子的光学制造
DOI：
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发表时间：
2015
期刊：
影响因子：
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通讯作者：
R. Wicker
中科院分区：
文献类型：
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作者：
Harrison Herzog;Jacob Segal;Jeremy J. Smith;R. Bates;Jacob Calis;A.I. Reyes de la Torre;Dae Wook Kim;Joni Mici;J. Mireles;D. Stubbs;R. Wicker
直接金属激光烧结（DMLS）和电子束熔化（EBM）3D打印技术被用于在图森的亚利桑那大学用AlSi 10 Mg铝和Ti6 Al 4V钛合金制造轻质光学级镜子。对反射镜原型进行抛光以满足λ/20 RMS和λ/4 P-V面形要求。该项目的目的是设计拓扑优化的反射镜，具有高比刚度和低表面位移。两个模型是使用Altair Mixire软件设计的，镜子必须经受抛光过程，具有必要的刚度，以消除印透。减轻3D打印镜坯的孔隙率是一项挑战，因为要将新的打印技术与传统的光学抛光方法相协调。原型经过热等静压（HIP）和热处理，以提高密度、消除孔隙率并释放内应力。金属3D打印允许对设计进行几乎无限的拓扑约束，并且在创建光学质量镜子时几乎不需要机械车间。这项研究可以导致在制造轻质反射镜时增加反射镜安装支撑复杂性，并提高整体工艺效率。该项目希望在未来有许多轻量化3D打印镜子的应用，例如航天。本文涵盖了3D打印反射镜的设计/制造/抛光/测试、热/结构有限元分析和结果。
Direct Metal Laser Sintering (DMLS) and Electron Beam Melting (EBM) 3D printing technologies were utilized to create lightweight, optical grade mirrors out of AlSi10Mg aluminum and Ti6Al4V titanium alloys at the University of Arizona in Tucson. The mirror prototypes were polished to meet the λ/20 RMS and λ/4 P-V surface figure requirements. The intent of this project was to design topologically optimized mirrors that had a high specific stiffness and low surface displacement. Two models were designed using Altair Inspire software, and the mirrors had to endure the polishing process with the necessary stiffness to eliminate print-through. Mitigating porosity of the 3D printed mirror blanks was a challenge in the face of reconciling new printing technologies with traditional optical polishing methods. The prototypes underwent Hot Isostatic Press (HIP) and heat treatment to improve density, eliminate porosity, and relieve internal stresses. Metal 3D printing allows for nearly unlimited topological constraints on design and virtually eliminates the need for a machine shop when creating an optical quality mirror. This research can lead to an increase in mirror mounting support complexity in the manufacturing of lightweight mirrors and improve overall process efficiency. The project aspired to have many future applications of light weighted 3D printed mirrors, such as spaceflight. This paper covers the design/fab/polish/test of 3D printed mirrors, thermal/structural finite element analysis, and results.