Topology optimization and additive manufacturing of an optical housing for space applications

Heidler, Nils; Lukowicz, Henrik von; Risse, Stefan; Alber, Lucas; Klement, Jan; Heine, F.; Bölter, Ralf; Armengol, Josep Maria Perdigués

doi:10.1051/epjconf/201921501005

Cited by 3 publications

(3 citation statements)

References 2 publications

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“…The connection between the prisms and the bipods is formed by Invar pins which are glued to both partners of the joint. To suppress stray light and disturbance light, the prisms are enclosed in two ultra-light and blackened covers, which are additively manufactured at the IOF using Selective Laser Melting (SLM) [2].…”

Section: Mechanical Designmentioning

confidence: 99%

Mechanical Integration of a Prism-Grating-Prism-Assembly for the CO2M Mission

Kamm

Scheffler²,

Peschel³

2022

EPJ Web Conf.

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We developed and realized a mechanical integration concept of a prism-grating-prism-assembly for the CO2M mission. The mechanical design of the mounts relies on a kinematic mounting of the optical elements. Additional, ultra-light and blackened covers for stray light and disturbance light suppression are included. The complete assembly was investigated by extensive thermo-mechanical simulations to verify the stability of the mechanical design under operational, launch loads and test conditions.

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Section: Mechanical Designmentioning

confidence: 99%

Mechanical Integration of a Prism-Grating-Prism-Assembly for the CO2M Mission

Kamm

Scheffler²,

Peschel³

2022

EPJ Web Conf.

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“…Hypereutectic Al-high Si alloys, especially with Si content > 30 wt.%, are characterized by preeminent properties, like low density, low thermal expansion, high hardness and stiffness, and excellent wear resistance, which enable numerous applications in the automotive, space and electronics industries [ 1 , 2 ]. All the alloy properties mentioned improve with increasing Si content, hence, there is high industrial interest regarding the commercial availability of AlSi-alloys with Si-content ≥ 50 wt.%.…”

Section: Introductionmentioning

confidence: 99%

Microstructure and Mechanical Properties of Hypereutectic Al-High Si Alloys up to 70 wt.% Si-Content Produced from Pre-Alloyed and Blended Powder via Laser Powder Bed Fusion

et al. 2023

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Hypereutectic Al-high Si alloys are of immense interest for applications in the automotive, space or electronic industries, due their low weight, low thermal expansion, and excellent mechanical and tribological properties. Additionally, their production by laser powder bed fusion (LPBF) technology provides high flexibility in geometrical design and alloy composition. Since, most of the alloy properties could be improved by increasing the Si content, there is much interest in discovering the maximum that could be realized in LBPF Al-high Si alloys, without the appearance of any material failure. For this reason, in this work the production of Al-high Si alloys with extremely high silicon content of up to 70 wt.% was fundamentally investigated with respect to microstructure and mechanical properties. Highly dense (99.3%) and crack-free AlSi50 samples (5 × 5 × 5 mm3), with excellent hardness (225 HV5) and compressive strength (742 MPa), were successfully produced. Further, for the first time, AlSi70 LBPF samples of high density (98.8%) without cracks were demonstrated, using moderate scanning velocities. Simultaneously, the hardness and the compressive strength in the AlSi70 alloys were significantly improved to 350 HV5 and 935 MPa, as a result of the formation of a continuous Si network in the microstructure of the alloy. With respect to the powder source, it was found that the application of powder blends resulted in similar alloy properties as if pre-alloyed powders were used, enabling higher flexibility in prospective application-oriented alloy development.

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“…In previous studies, Heidler et al 8 demonstrated that topology optimisation and AM can be used to reduce the mass of an optical housing for a space application by 20% and Frasch et al 3 used generative design tools to optimise the design of the structure for a three-mirror beam expander. In Frasch et al the original component was 150 mm×90 mm×90 mm weighing 0.5 kg.…”

Section: Introductionmentioning

confidence: 99%

Lightweighting large optomechanical structures in astronomy instrumentation utilising generative design and additive manufacturing

Wells,

Westsik,

Chahid

et al. 2023

Optomechanical Engineering 2023

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Ground-based astronomical instruments have mass limits to ensure they can operate safely and accurately. Reducing the mass of optomechanical structures relieves mass budget for other components, improving the instrument's performance. Many industries have adopted generative design (GD) and additive manufacturing (AM; 3D printing) to produce lightweight components. This is yet to be implemented in ground-based astronomical instrumentation; this paper aims to provide insight into the advantages and limitations of this approach. The project studied the Extremely Large Telescope (ELT) Mid-infrared Imager and Spectrograph (METIS) threemirror anastigmat (TMA); comparing the conventional, subtractive machined design with GD-AM designs. The TMA was selected due to its bespoke geometry constrained by an optical path, a conventional design which did not consider mass reduction, the size of the part (615 mm × 530 mm × 525 mm) that necessitated a study of different AM methods, and the operational environment (70 K & 10 −6 Pa).The study created mass-optimised designs of the TMA using topology optimisation and field-driven design. The performance of these designs was analysed using finite element analysis and optical ray tracing. It was found that GD-AM designs pass the required optical, structural and modal requirements, with a greater than 30% weight reduction when compared to the conventional design. The study investigated wire arc additive manufacturing (WAAM), a viable method of manufacturing components of the TMA's size. To commence the validation of WAAM for cryogenic environments, samples of WAAM aluminium 5356 were created and studied. The internal and external dimensions of two samples were investigated using X-ray computed tomography and the outgassing rate of two sets of three samples were evaluated to quantify the difference between machined and as-built samples.

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Topology optimization and additive manufacturing of an optical housing for space applications

Cited by 3 publications

References 2 publications

Mechanical Integration of a Prism-Grating-Prism-Assembly for the CO2M Mission

Mechanical Integration of a Prism-Grating-Prism-Assembly for the CO2M Mission

Microstructure and Mechanical Properties of Hypereutectic Al-High Si Alloys up to 70 wt.% Si-Content Produced from Pre-Alloyed and Blended Powder via Laser Powder Bed Fusion

Lightweighting large optomechanical structures in astronomy instrumentation utilising generative design and additive manufacturing

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