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

Transcription

1 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 17 dicembre 2010 Agenzia Spaziale Italiana Giuseppe Borghi giuseppe.borghi@media lario.com 1 Source: MLT, Dec-10, Page 1

2 Media Lario Technologies lario.com Lecco Italy High precision optics from Microwave and IR through Visible to EUV and X

3 MEDIA LARIO TECHNOLOGIES A SUCCESSFUL EXAMPLE OF AN ITALIAN SPACE TECHNOLOGY SPIN OFF. CONTINUOUS AND SYNERGISTIC TECHNOLOGY EVOLUTION FROM SPACE TECHNOLOGIES TO INDUSTRIAL APPLICATIONS & VICE VERSA. From the XMM Mission High Precision 58 shell Nested Mirrors Complex Structure Electroforming Eng. Shape, Thermal & Structural control X Ray Reflective Surface & Material Tech. High Accuracy Replication Manufacturing System Integration and Testing The Space Technology Spin off XMM Newton / X Ray Telescope The most powerful X ray X Telescope ever built Prof. Dr. Roger Bonnet, ESA Director of Science, Kourou, 10 Dec. 99. XMM Newton TERRESTRIAL TELESCOPES IMAGING OPTICS EUV LITHOGRAPHY Source: MLT, Dec-10, Page 3

4 MLT s unique selling proposition is its ability to produce high precision optics in a replicable process using electroforming, where one form or mandrel is used to reproduce multiple identical mirrors. This methodology saves >50% in cost & cycle time compared to traditional grinding and polishing. OPTICS MANUFACTURING CONVENTIONAL Bulk material Grinding Polishing Optical Coatings Conventional Manufacturing One at the time method Yield variations Long cycle time High cost for high accuracy OPTICS MANUFACTURING Media Lario s ELECTROFORMING REPLICATION Mandrel manufacturing Replication MLT optics manufacturing Bulk material Diamond turning Polishing Electroforming Separation Optical Coatings High precision replication High yield Short cycle time Cost effective Integrated thermal control Mandrel reused Source: MLT, Dec-10, Page 4

5 E forming is competing with D T & other optical finishing techniques on the high end and glass stamping on the low end. MLT s technology + manufacturing roadmap pushing e forming towards high end performance and for High Precision mirrors. In 2009 MLT exceed Imaging/Non Imaging performance threshold enabling a new series of applications Increasing Recurrent Product Cost Non imaging applications SPACE & TERRESTRIAL TELESCOPE PLASTIC STAMPING GLASS STAMPING MLT E FORMING CAPABILITIES EUVL COLLECTOR MEDICAL Imaging applications DIAMOND TURNING MAGNETO RHEOLOGICAL FINISHING GLASS POLISHING DEFENSE EUV LITHO LASER APP Diffraction limited ~5λ λ λ/2 λ /4 λ /8 λ/16 ION BEAM FIGURING <λ/100 Decreasing wave front error (@ 632 nm) Source: MLT, Dec-10, Page 5

6 NORMAL INCIDENCE MIRRORS REACHED PERFORMANCES λ/16 RMS and λ/4 PTV over 150mm and 1 2 mm substrate thickness Better than λ/6 PTV on 100 mm clear aperture Source: MLT, Dec-10, Page 6

7 MARKET ANALYSIS Market Attractiveness External drivers Applications assessment Earth Observation 2 Space Exploration Airborne 1 Surveillance b EUV Collector (NIC) + Illuminator Mirrors 13 EUV Collector (GIC) 21 Today S&T Applications 31 Medical Optical Scanners KEY PLAYERS PRODUCTS Recon Component providers Connectors Missile Optical Subsystem Sub-systems provider Aircraft Warfare equipment provider Helicopter Navy, Aeronautics & Army Optical Scanner 0 0 Legend MLT Capability Internal drivers Pointer Mirrors Optical camera Submarine Tank Under development New applications Today s position Note: External drivers take in consideration market size, market growth, pricing position and competitive pressure - Internal drivers takes in consideration technological and operational MLT capabilities mln 1,150 1,100 1,050 1, % 500 6% Note: 51% 29% 13% 2009 Total Addressable Market 571 1% 6% 50% 30% 14% 2010 Combat UAVs 652 1% 8% 47% 31% 13% % 747 1% 9% 45% 31% 14% % 13% 42% 30% 12% 2016 Surveillance UAVs 987 5% 17% 40% 29% 9% ,139 10% 21% 37% 28% 4% % 20% 4% 7% -5% Guided missiles and bombs Market outlook The AS&ST Market is worth about 535 mln and is forecasted to growth at 8% CAGR overall Today optical systems are mainly based on mixed technologies (reflective and refractive) 5 Surveillance and Combat UAVs: 4 Solid growing market still in R&D phase Main defence players and organizations are pushing the technological evolution 3 Guided missiles and bombs: Mature market dominated by few consolidated players The growth rate is foreseen not to change up to Helicopters: Mature market dominated by few consolidated players The growth rate is foreseen to slow down after 2015 due to the potential substitution with UAVs for surveillance missions 1 Fighters: Declining market due to the manned fighter substitution with unmanned, remote controlled UAVs (according with DoD) The market is currently moving from 4th to 5th generation fighters (F-35) which will dominate the decade Helicopters Fighters Chevraux defense market overview 2009, Jane industry quarterly 2009, Credit Suisse 2009 and first outlook 2010, Booz & Company analysis. JDPs are not considered in TAM & SAM calculation. TAM and SAM represent the market value of optical subsystems for AS&TA (Airborne Surveillance and Targeting Acquisition) solutions Source: MLT, Dec-10, Page 7

8 TARGET SECTOR AND APPLICATIONS Space Exploration Earth Observation Sistemi ottici per missioni di esplorazione del Sistema Solare su pianeti o altri corpi celesti Sottosistemi ottici ad elevato angolo di campo per payload multispettrali o Iperspettrali Surveillance SistemidiGuida Sistemi ottici multispettrali per applicazione di Difesa Surveillance Targeting basati su approccio riflettivo Sistemi ottici altamente asferici per i sistemi di puntamento di missile e bombe guidate Source: MLT, Dec-10, Page 8

9 VALUE PROPOSITION MULTISPECTRAL/HYPERSPECTRAL VIS FIR LOW MASS LOW RECURRENT COSTS HIGHLY ASPHERICAL LOW ROUGHNESS THIN MIRRORS BY REPLICA Source: MLT, Dec-10, Page 9

10 PRODUCT ROADMAP Exploration Phase Focus on EUROPE market Focus on Surveillance Develop understanding of products requirements Value Proposition Assessment Definition of Strategies and tactics wrt Customers Perforn Optical and Mechanical design of the functional demonstrator Preliminary engagment Phase Obtain Customer Preliminary engagment on Value Proposition Development of Functional Demonstator Development of relationships via meetings, conferences, events Seek for engagment in Italian players Evaluation of other customers Look for partenrships with Customers and Suppliers Product Specification from Customer Novel Optical design Final Engagment Phase Engagment for the Product Demonstrat\or as a precursor of the Product Prototype Eventual engagment at component level Business development targeted to theengagment ofsecond customer Design & Technology Patent JDP on Product Demonstrator Functional Demonstrator Development Functional Demonstrator Optical & Mechanical design of functional demonstrator Start of the project - Start of first level engagement with a customer - Technological and market Go/ no go and JDP Source: MLT, Dec-10, Page 10

11 BY IMPROVING THE COMPACTNESS AND INCREASING THE NUMBER OF OPERATING WAVELENGTHS, MLT CAN ENABLE WEIGHT, SIZE AND COST REDUCTION WITH SUPERIOR OPTICS PERFORMANCE Traditional Traditional refractive refractive approach approach MULTI-SPECTRAL OPTICAL MODULE All All reflective reflective standard standard approach approach All All reflective reflective MLT MLT approach approach One optical module per wavelength band Single module Single module Main Main challenges challenges Two approaches are possible : 1. Multiple achromatic refractive subsystems 2. One single module using high cost material (E.g. ZnSe, ZnS) Both costly and with high number of components, causing high weight and large volume All All reflective reflective Benefits/Challenges Benefits/Challenges One single optical module operating at the two IR (3-5 μm and 8-12 μm ) and visible near IR ( μm) bands Difficult/costly for volume production with standard technology due to the need of highly aspheric optics MLT MLT Technological Technological Breakthroughs Breakthroughs Faster and reduced cost product deployment (i.e. lead time or cost) Overcome technology showstopper (i.e. highly aspheric optics, low weight, low roughness) New design for a new product (i.e. single multispectral optical module) Source: MLT, Dec-10, Page 11

12 SEVERAL EXAMPLE OF ALL REFLECTIVE DESIGN FOR SURVEILLANCE AND EARTH OBSERVATION APPLICATIONS HAS BEEN DEVELOPED ALL WITH REMARKABLE PERFORMANCES AND ENABLED BY MLT E FORMING TECHNOLOGY (PATENT PENDING) Design of an all reflective imaging system for an high resolution application All mirrors surfaces are generally highly aspherical and off axis The example is designed to suit fast narrow angle FOV type applications OPTICAL DESIGN EXAMPLE EXAMPLE OF OPTICAL MODULE DESIGN EXAMPLE DESCRIPTION Wavebands of operation: Effective Focal Length: VIS to LWIR ( µm) 98 mm F/no: 1.3 Entrance Pupil: Field of view (FOV): Sensor Size: Sensor VIS NIR: Sensor LWIR: MTF (visible & NIR) : MTF (MIR & LWIR) : Zero Vignetting DEVICE EXAMPLE CHARACTERISTICS Ø 75mm 7.6 x 4.8 (Ø9.0) 15.2 x 10.1mm (Ø18.3mm) 10 μm pixel ~1500 pixels (H) 25 μm pixel ~600 pixels (H) > cyc/mm over whole FOV > cyc/mm over whole FOV Source: MLT, Dec-10, Page 12

13 FUNCTIONAL DEMONSTRATOR Source: MLT, Dec-10, Page 13

14 PROJECT GANNT ID Task Name 1 Milestones 2 KO 3 RR 4 PDR 5 CDR 6 TRR 7 TRB 8 Final Meeting 9 SS Reviews 16 Attività Progetto 17 WP 1001 & WP WP 1003 Ricerca Tecnologica & Trade-off's 21 Analisi dei requisiti applicazioni di riferimento 22 Generazione requisiti dei dimostratori 23 Generazione iterativo del design ottico 24 Analisi delle tolleranze amissibili dei mirrors 25 Trade off's 31 Allocazione dei requisiti ai singoli sviluppi tecnologici 37 Piani e procedure di verifica 41 WP 1004 Tailoring Tecnologia Mandrini 42 Analisi scientifico/tecnologica per realizzazione mandrini 43 Definizione approccio metrologico per mandrini 44 Design mandrini 45 PDR mandrini 46 Realizzazione mock-up mandrini 47 CDR mandrini 48 Realizzazione mandrini 49 WP 1005 Tailoring Tecnologia Specchi 50 Simulazione processo di eforming 51 Progettazione toolings 52 Realizzzione toolings 53 PDR eforming 54 Progettazione bagno di eforming 55 Modifica bagno di eforming 56 CDR eforming 57 Disponbilità mandrino mock-up 58 Ottimizzazione processo di eforming su mandrino mock-up 59 Disponibilità mandrini finali 60 Ottimizzazione processo di eforming su mandrini finali 61 Produzione e verifica mirrors per dimostratore 62 WP 1006 Tailoring Tecnologia Optomeccanica 72 WP 2001 AIV dimostratore precommerciale Q1 Q2 Q3 Q4 Q1 Q2 M-1 M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M12 M13 M14 M15 M16 M17 14 Source: MLT, Dec-10, Page 14

15 CONCLUSIONS AND EXPECTED RESULTS MLT and ASI will jointly perform an Industrial Research activity for the design and prototyping of highly aspherical optical components for Multispectral and Hyperspectral sensors for Space and Defense Applications. Expected Results Extended MLT and Italian sector technology portfolio exploiting MLT innovative technologies for next generation optical products Design and manufacturing of TRL4 prototype of a full reflective Multispectral Functional Demonstrator (from Visible to FIR) optical module with highly aspherical electroformed optical components demonstrating strong mass and size reduction of the optical module and providing superior performances Source: MLT, Dec-10, Page 15

16 THANKS GIUSEPPE BORGHI LARIO.COM Source: MLT, Dec-10, Page 16