Sviluppo di componenti per sottosistemi ottici basati su ottiche elettroformate altamente asferiche per applicazioni Spazio e Difesa

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Job Tucker
8 years ago
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Spazio e Difesa Workshop Terzo bando P.M.I.

1 EMSOM Sviluppo di componenti per sottosistemi ottici basati su ottiche elettroformate altamente asferiche per applicazioni Spazio e Difesa Workshop Terzo bando P.M.I. Tema Materiali, Componenti e Sensori Roma, 25 Luglio 2013 Roma, 25 July 2013 Page 1

Manufacturing System Integration and Testing Space Spin-off The most powerful X-ray Telescope ever built Prof. Dr.

2 Media Lario Technologies: A successful example of an Italian Space Spin-off High Precision 58-shell Nested Mirror Systems Complex Structure Electroforming Engineering Shape, Thermal & Structural control X-Ray Reflective Surface & Material High Accuracy Replication Manufacturing System Integration and Testing Space Spin-off The most powerful X-ray Telescope ever built Prof. Dr. Roger Bonnet, ESA Director of Science, 10 Dec. 99. XMM-Newton New Generation Lithography Terrestrial Telescopes; Surveillance & Security (Defense, Commercial) Page 2

Complex Optical Systems for Defense and Space Applications featuring highly aspherical surfaces Surveillance Guidance Systems Multispectral optical systems based on reflective approach for Defense

3 Complex Optical Systems for Defense and Space Applications featuring highly aspherical surfaces Surveillance Guidance Systems Multispectral optical systems based on reflective approach for Defense Surveillance Targeting applications. Highly aspherical optical systems for targeting systems of missiles and guided bombs Space Exploration Earth Observation Optical subsystems for Solar System exploration missions of planets or other celestial bodies Wide angle camera optical subsystems for multispectral and hyperspectral payload Page 3

Highly aspherical optical systems for targeting systems of missiles and guided bombs Space Exploration Earth Observation Optical

4 Conventional systems vs. MLT electroformed approach enabling weight, size and cost reduction Traditional Refractive Approach Standard All-reflective Approach MLT eformed Approach Multiple chromatic refractive systems or one single module using high cost materials (ZnSe,ZnS) Costly and heavy with several components and large envelopes One single optical module operating for different wavebands Highly complex optical surfaces needed with difficult/costly manufacturing Overcomes manufacturing issues by adopting eforming replication (i.e. highly aspheric optics, low weight, low roughness with fast deployment and reduced costs) Page 4

$Multiple chromatic refractive systems or one single module using high cost materials (ZnSe,ZnS) Costly and heavy with several components and large envelopes$

High precision replication by eforming enables breakthrough performance with complex profiles providing cost and cycle time advantages CONVENTIONAL OPTICS MANUFACTURING PROCESS

variations Long cycle time High cost for high accuracy MLT optics manufacturing yields MULTIPLE replicated optics High precision replication Free form High yield Short cycle time

5 High precision replication by eforming enables breakthrough performance with complex profiles providing cost and cycle time advantages CONVENTIONAL OPTICS MANUFACTURING PROCESS Optics Manufacturing Optical Coating Bulk Material Input Precision Machining Polishing Conventional manufacturing process yields 1 optic unit One-at-the-time method Yield variations Long cycle time High cost for high accuracy MLT optics manufacturing yields MULTIPLE replicated optics High precision replication Free form High yield Short cycle time Cost effective REPLICATION BY ELECTROFORMING OPTICS MANUFACTURING PROCESS Mandrel Manufacturing Replication Optical Coating Precision Machining Polishing Coating Bulk Material Input Page 5

6 To this we combine our unique freeform figuring, polishing, and metrology Media Lario s free-form figuring and polishing process Mandrels, reflective and refractive optical components Precision Machining Shape Metrology Deterministic Figuring & Polishing Reflective Coating Final Metrology Outsourced Customized profile metrology with 50 nm precision /40 interferometer CNC polishing process driven by metrology 1.2 m diameter In-house and outsourced 800 mm PVD sputtering system 1 m ebeam evaporation coating systems Customized optical benches for final verification 800 mm HSFR = 0.2 nm Accuracy = λ/40 rms Highly aspheric Non rotationally symmetric Page 6

with 50 nm precision /40 interferometer CNC polishing process driven by metrology 1.

7 From optical design to thermo-elastic analysis and optical simulation to guarantee specific product requirements and final performance TMA Optical Design Designed for MIL-STD-810G jet take-off and helicopter continuous flight with simulations for 5g static load and 32 C uniform thermal variation F/1.4 on Vis, NIR, MIR and LWIR with 136 mm focal length, and 94 mm aperture FoV up to Ø5.5 and 2.6 kg. Nominal performance >70% MTF at Nyquist frequencies in VIS and IR Thermo-elastic simulation of operational conditions Athermal design based on RSP Al alloys CTE matched with the mirror substrate Full assembly 1 st eigenfrequency >230 Hz Mirror first eigenfrequency >900 Hz Page 7

4 on Vis, NIR, MIR and LWIR with 136 mm focal length, and 94 mm aperture FoV up to Ø5.5 and 2.6 kg.

Test of the Functional Demonstrator proved both the design concept and manufacturability advantages Integrated Functional Demonstrator MTF measurements in visible demonstrates concept feasibility

8 Test of the Functional Demonstrator proved both the design concept and manufacturability advantages Integrated Functional Demonstrator MTF measurements in visible demonstrates concept feasibility Measured MTF at F/2.8 is above 50% on 80% of the FOV IR predicted performance is above 60% MTF for MWIR and close to diffraction limit in the LWIR Higher MTF performances are possible by further optimization of manufacturing and integration process USAF-1951 F/2.8 Page 8

$8 is above 50% on 80% of the FOV IR predicted performance is above 60% MTF for MWIR and close to diffraction limit in$

9 EMSOM penetration into the Defence and Space market Thanks to Agenzia Spaziale Italiana, Media Lario has developed an innovative TMA design and a manufacturing solution for lightweight single-aperture, multi-fov, multi-spectral sensors operating from Visible to LWIR with high performance in a compact envelope with cost and cycle time advantages EMSOM has triggered the interest of North American Defense companies and its technology that of European Space companies. The project results have been presented in April at the SPIE Defense, Security, and Sensing Conference Media Lario was invited to present the demonstrator at the Rayteon ELCAN booth for live demo. Media Lario has and continues to be engaged with an industrial partner to evolve EMSOM into a fully fledged product. However the recent decision of the US administration to reduce the defense budget (Sequestration) has slowed down the R&D investments and this has pushed out the sought industrial engagement by 12 months. Page 9

North American Defense companies and its technology that of European Space companies. The project results have been presented in April at the SPIE Defense, Security, and Sensing Conference 2013.

Workshop 1 Bando Tematico riservato alle P.M.I. Materiali, Componenti, Sensori

Workshop 1 Bando Tematico riservato alle P.M.I. Materiali, Componenti, Sensori Sviluppo di componenti per sottosistemi ottici basati su ottiche elettroformate asferiche per applicazioni Spazio e Difesa