The next generation wide-field X-ray telescope (WFXT), to be implemented beyond eRosita and proposed within the NASA RFI call 2011, requires an angular resolution of less than 10 arcsec (with goal of 5") constant across a wide field of view (1 deg 2 ). To achieve this requirement the design is based on nested modified grazing incidence Wolter-I mirrors with polynomial profiles. Our goals in terms of mass and stiffness can be meet with the use of fused silica glass, a wellknown material with good thermo-mechanical properties and polishability characteristics, together with an innovative polishing approach. Here we present the X-ray calibration results obtained for a prototypal shell tested in fullillumination mode at the Panter/MPE facility.

This study examines the viability of using additively manufactured injection molding tools for short run proof-ofconcept plastic parts by assessing the quantity and quality of molded parts. Prototyping injection molded parts traditionally can be very expensive, but with improved additive manufacturing materials and techniques such costs could be reduced. To prove this, plastic tools were made by using PolyJet and Fused Deposition Modeling out of Digital ABS, FullCure 720, and ULTEM 1010 materials in this study. The test tools were then compared to the standard P20 metal tool by molding acetal, polycarbonate (PC), and polypropylene (PP) in each tool type. The molded parts were analyzed for processing effects on part shrink, physical, and mechanical properties. Testing concluded that parts molded with additively manufactured tools performed comparably to parts made on a P20 tool. However, the quantity of satisfactory parts molded in acetal and PC were consistent with the literature at 10-100 parts. Conversely, molding in PP suggested that processing with additive manufactured tools could exceed 250 parts.

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Stereolithography (SLA) is a widely utilized rapid additive manufacturing process for prototypes and proof-of-concept models with high resolution. In order to create structurally sound components using SLA, reinforcement needs to be incorporated in the UV-based resins typically used. However, the introduction of reinforcement into vat-based SLA printers has had limited success due to a host of processing challenges including the creation of a homogeneous resin mixture and UV-inhibiting constituents. The effectiveness of using a dual curing system, consisting of a photo and thermal initiator, for the additive manufacturing of carbon fiber short-fiber composites via vat photopolymerization, was investigated. The necessary processing parameters were developed that resulted in successful printing and curing of composites at a 5% fiber volume. Manufacturing with reinforcements that have different densities from the resin creates separation issues, either suspending to the top or settling to the bottom. Following the approaches discussed in this chapter, an even distribution of short fibers was achieved throughout SLA printed samples using a modified commercial printer. Separation was overcome by inducing a continuous flow of reinforced liquid resin in the printer vat during printing. This flow field adaptation allows commercial SLA printers the ability to produce composite parts with different densities of the constituents utilized.