In the development of space-based large telescope systems, having the capability to perform active optics correction allows correcting wavefront aberrations caused by thermal perturbations so as to achieve diffraction-limited performance with relaxed stability requirements. We present a method of active optics correction used for current ground-based telescopes and simulate its effectiveness for a large honeycomb primary mirror in space. We use a finite-element model of the telescope to predict misalignments of the optics and primary mirror surface errors due to thermal gradients. These predicted surface error data are plugged into a Zemax ray trace analysis to produce wavefront error maps at the image plane. For our analysis, we assume that tilt, focus and coma in the wavefront error are corrected by adjusting the pointing of the telescope and moving the secondary mirror. Remaining mid- to high-order errors are corrected through physically bending the primary mirror with actuators. The influences of individual actuators are combined to form bending modes that increase in stiffness from low-order to high-order correction. The number of modes used is a variable that determines the accuracy of correction and magnitude of forces. We explore the degree of correction that can be made within limits on actuator force capacity and stress in the mirror. While remaining within these physical limits, we are able to demonstrate sub-25 nm RMS surface error over 30 hours of simulated data. The results from this simulation will be part of an end-to-end simulation of telescope optical performance that includes dynamic perturbations, wavefront sensing, and active control of alignment and mirror shape with realistic actuator performance.
The Richard F. Caris Mirror Lab at the University of Arizona continues production of 8.4 m lightweight honeycomb segments for the primary mirror of the Giant Magellan Telescope. GMT’s 25 m primary mirror consists of a center segment surrounded by six off-axis segments, with an additional off-axis segment to allow continuous operation as segments are removed for coating. We cast the sixth segment (5 off-axis segments + center segment) in March 2021. As of June 2022 we have tentatively completed polishing of the third off-axis segment, and we are in the process of grinding the optical surface of off-axis Segment 5. For Segment 3, we improved the measurement accuracy for small-scale structure near the edge of the mirror, which has been a challenge for the off-axis segments. In addition to full-aperture interferometry and deflectometry, we used a 20 cm test plate to obtain high-resolution interferometric measurements of the edge.
Additive manufacturing, or 3D printing, has become widely used in recent years for the creation of both prototype and end-use parts. Because the parts are created in a layer-by-layer manner, the flexibility of additive manufacturing is unparalleled and has opened the design space to enable features like undercuts and internal channels which cannot exist on traditional, subtractively manufactured parts. This flexibility can also be leveraged for optical applications. This paper outlines some of the current uses of 3D printing in the optical manufacturing process at Optimax. Several materials and additive technologies are utilized, including polymer printing through fused deposition modeling, which creates parts by depositing a softened thermoplastic filament in a layerwise fashion. Stereolithography, which uses light to cure layers of a photopolymer resin, will also be discussed. These technologies are used to manufacture functional prototypes, fixtures, sealed housings, and other components. Additionally, metal printing through selective laser melting, which uses a laser to melt metal powder layers into a dense solid, will be discussed due to the potential to manufacture thermally stable opticalmechanical assembly frameworks and functional optics. Examples of several additively manufactured optical components will be shown.
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