In high-precision refractive optical systems, e.g. telescopes and spectrometers for space applications, temperature differences in influence the optical performance in the form of aberrations, especially thermal defocus. By temperature changes not only the radii of the optical elements itself, but also the distances between the optical elements are changing in dependency of the used mount materials. This causes a thermal defocus of the system and needs to be compensated. There are multiple approaches for compensation, generally divided into active and passive compensation. Active compensation techniques, e.g. piezo actuators, are highly accurate but require a control system, which is a cost and complexity driver. Passive compensation techniques often use combinations of several materials with different coeffcients of thermal expansion. This increases the overall complexity and mass. The focus of this research is to develop a mechanical structure that passively compensates for thermal defocus over a wide temperature range. Auxetic unit cells are the basis of this structure. Auxetic structures exhibit a negative Poisson´s ratio. By three-dimensional combination of auxetic unit cells, these can be arranged in a way that a transformation from radial deformation into longitudinal deformation is realized. The geometrical complexity requires additive manufacturing as manufacturing process. This concept is used to develop a mounting structure that passively compensates for thermal defocus by opposing longitudinal deformation, which is triggered by the thermally induced radial deformation of the structure itself under temperature changes. By analytical and numerical investigations, the mechanical behavior of the auxetic cells is studied in dependency of geometrical parameters. With these results, an auxetic mounting structure is developed. The aim is to compensate 5 μmK-1 axial spacing over a temperature range of 80 K. For proof of concept, a demonstrator system is numerically investigated under thermal loads and on its structural-dynamic properties.
The current paper describes the optical and mechanical design of a compact Three-Mirror Anastigmate (TMA) telescope which is installed at the ISS as an earth observation demonstrator for the thermal-infrared spectral range. The TMA bases on a Korsch type design. It has a focal length of 150 mm and an aperture of F/3 and allows for a diffraction limited performance at the design wavelength of 10 μm. The ground resolution reaches 80 m from the ISS. The mechanical design fits into a design space of 80x80x150 mm3 which would correspond to 1.5 U of a typical CubeSat for the telescope or 3U for the whole instrument, respectively.
KEYWORDS: Spectroscopy, Sensors, Carbon dioxide, Mirrors, Optical design, Radio optics, Space operations, Signal to noise ratio, Imaging systems, Aerospace engineering
CO2Image is a satellite demonstration mission, now in Phase B, to be launched in 2026 by the German Aerospace Center (DLR). The satellite will carry a next generation imaging spectrometer for measuring atmospheric column concentrations of Carbon Dioxide (CO2). The instrument concept reconciles compact design with fine ground resolution (50-100 m) with decent spectral resolution (1.0-1.3 nm) in the shortwave infrared spectral range (2000 nm). Thus, CO2Image will enable quantification of point source CO2 emission rates of less than 1 MtCO2/a. This will complement global monitoring missions such as CO2M, which are less sensitive to point sources due to their coarser ground resolution and hyperspectral imagers, which suffer from spectroscopic interference errors that limit the quantification.
The GALA (Ganymede Laser Altimeter) is one of eleven scientific instruments of the ESA mission JUICE (Jupiter Icy Moons Explorer) with the goal of exploring the icy moons of Jupiter, with a special interest in Ganymede. By its atmosphere, magnetic field, and water abundance, Ganymede is similar to Earth [1]. GALA is a laser altimeter that generates a surface profile with a resolution of < 15 cm based on an emitted laser pulse that is reflected by the surface of the moon 500 km away [2]. The mechanical development of the receiver telescope with an extremely thin-walled primary mirror (thickness 4-8 mm; diameter ~ 300 mm) was driven by tough boundary conditions. These are a small envelope and mass budget with high mechanical loads, such as a quasi-static acceleration of 120 g during rocket launch and a temperature range from -50 °C up to 150 °C, at the same time. The athermal design is based on the use of a silicon particle reinforced aluminum compound (AlSi40) and an amorphous nickel-phosphorous plating to allow various shape correction and polishing processes. Another challenge was the high radiation load of 1012 protons/cm2 @ 10 MeV. Fraunhofer IOF developed and qualified a gold HR coating based on nanolaminate with R < 98% @ 1064 nm and high resistance. Thus, almost all process steps from development through manufacturing to integration and characterization could be carried out at Fraunhofer IOF. With a shape deviation of 27 nm RMS of the primary mirror and 8 nm RMS of the secondary mirror, a system performance of 90% encircled energy could be achieved with a pupil radius of 38 µm. The telescope was handed over to HENSOLDT in spring 2020 and will start its eight-year journey to Jupiter in 2023.
The high precision Slit Assembly is a key component of the FLEX instrument. Two different input beams for the Low- and the High-resolution spectrometer, respectively, will be generated by the Slit assembly. The paper presents design and implementation of its optical key components, which are a highly precise double slit and two mirrors achieving spatial channel separation and spectral filtering. High alignment and stability requirements, as well as stringent envelope restrictions are driving the mechanical design of the Slit Assembly. We demonstrate solutions in design and manufacturing techniques as well as achieved performance under thermal and mechanical loads. The main focus of the paper is on the development and realization of the double slit device. This device is designed to mount a silicon double slit chip into a mechanical holder providing mechanical and gauge interfaces to the slit assembly. The slit position is aligned to mechanical interfaces to meet the tight positioning requirements. A dedicated lithographic structuring process chain was developed for the manufacturing of the double slit to fulfill a number of challenging requirements; i.e. the absolute slit width accuracy of less than 2 μm peak to valley, and slit planarity of less than 10 μm peak to valley. It is based on the adaptation of lithographic structuring techniques for etching of Silicon wafers. The overall manufacturing process is the result of an extended technology development phase. The manufactured slits are coated with a black coating layer to reach the specified optical reflectivity and the optical density. The results of environmental tests of the Double slit device Breadboard, i.e. the thermal vacuum test, the shock test, and the vibration test, are discussed.
Gold shows a very high reflectivity in the IR range. In addition, Au (and protected Au) is more robust than Ag (and protected Ag). Therefore, Au based coatings are of high interest. Common techniques for the deposition of optical Au coatings are sputtering and evaporation. In this contribution, both techniques, sputtering and evaporation, as well as unprotected and protected Au will be considered. A comparison of reflectivity between sputtered and evaporated Au-layers shows a slightly higher reflectivity for evaporated Au.
Beside reflectivity after coating, decrease of reflectivity due to interdiffusion at increased temperatures (250°C) between adhesion layer and the reflective Au-layer is considered. In case of space-based applications, interdiffusion in thin film coatings could be activated due to particles of lower energies. This phenomenon is not necessary tested by radiation tests, performed by applying particles of higher energy. By a sputterd TiOX adhesion layer underneath a protected Au-coating (protected by an Al2O3-Si3N4-laminate), resistance against interdiffusion, and the successful passing of radiation-, cleanability- and abrasion tests could be achieved. This high reflective coating (reflectivity of 98 % at 1064 nm) was applied to the different mirrors of the GALA-instrument.
The development of mechanical structures for space telescopes is mainly driven by reducing the mass and in the same step increasing the stiffness, thus to achieve a high margin of safety against failure during launch and low costs for the satellite mission. These aspects attract more and more attention for the NewSpace movement, e.g. for constellations of earth observation and communication systems. Considering the state of the art, design of mass-reduced housings is limited by conventional manufacturing processes like CNC-milling. The possibility of additive manufacturing of metallic materials opens the door for an advanced light-weighted design based on topology optimization and thereby an ideal use of the existing material, which is distributed to optimally sustain loads occurring during launch. This article deals with the development, manufacturing and test of a three-mirror-anastigmatic telescope. In more detail, different concepts for light-weighting (topology optimization and a more traditional shell concept) will be presented. After the additive manufacturing of the AlSi40-mirrors and AlSi40-housing, the parts can be further processed by the typical process chain (e.g. single-point-diamond-turning, plating with electroless nickel), as known from high-performance optics. After integration, the mechanical behaviour will be verified with dynamic tests using a shaker and the results (e.g. the eigenfrequencies) will be compared with simulations finite-element analysis and an optical characterization will be carried out.
Metal mirrors are used for spaceborne optical systems, such as telescopes and spectrometers. In addition to the optical performance, the mechanical needs and the mass restrictions are important aspects during the design and manufacturing process. Using the additive manufacturing process, optimized internal lightweight structures are realized to reduce the weight of the system while keeping the mechanical stability. A mass reduction of ≈60.5 % is achieved. Using the aluminum silicon alloy AlSi40, the thermal mismatch of the mirror base body to a necessary electroless nickel-polishing layer is minimized. Based on an exemplary mirror design, the optimization of the interior lightweight structure is described, followed by the manufacturing process from additive manufacturing to diamond turning, plating, and polishing. Finally, the results of surface metrology and light scattering measurements are presented. A final form deviation below 80 nm p . − v . and a roughness of ∼1 nm rms could be demonstrated.
Additive manufacturing enables enhanced designs for metal mirrors and housings of optical systems like telescopes. Internal lightweight structures are used for the mirror modules to reduce the weight of the system while keeping the mechanical stability. Internal structures can be produced by selective laser melting, which cannot be realized by conventional machining. Using an aluminum silicon alloy, the thermal mismatch of the mirror base body to the necessary polishing layer is minimized. Resulting thermal induced deformations are greatly reduced. The additive manufacturing of a mirror module with two optical surfaces is described in detail. Using a adapted process chain for the application in the visible range, first results of the additive manufacturing as well as subsequent machining steps like diamond turning of the optical surfaces are presented.
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