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Additive manufacturing and high resolution X-ray optics Carolyn Atkins STFC Rutherford International Fellow/ Marie Skłodowska-Curie fellow STFC – UK Astronomy Technology Centre [email protected] 9th International workshop on astronomical x-ray optics, Prague, Czech Republic, 7th Dec 2016 Presentation outline Introduction Additive manufacturing of optics Additive manufacturing of X-ray optics Research plan Summary and conclusion Presentation outline Introduction Additive manufacturing of optics Additive manufacturing of X-ray optics Research plan Summary and conclusion Rutherford International Fellowship STFC Rutherford International fellow / Marie Skłodowska-Curie fellow http://www.stfc.ac.uk/funding/fellowships/rutherford-international-fellowship-programme/ A two year fellowship for non-UK citizens residing outside the UK (…or UK citizens who resided outside the UK for 3+ years) to be located at an STFC laboratory: • The Rutherford Appleton Laboratory • The Daresbury Laboratory • UK Astronomy Technology Centre (UKATC) • Chilbolton Observatory. Rutherford International Fellowship STFC Rutherford International fellow / Marie Skłodowska-Curie fellow http://www.stfc.ac.uk/funding/fellowships/rutherford-international-fellowship-programme/ A two year fellowship for non-UK citizens residing outside the UK (…or UK citizens who resided outside the UK for 3+ years) to be located at an STFC laboratory: • The Rutherford Appleton Laboratory • The Daresbury Laboratory • UK Astronomy Technology Centre (UKATC) • Chilbolton Observatory. My Fellowship project at the UKATC Title: Additive manufacturing of astronomical components What is additive manufacturing? Additive manufacturing = 3D printing ‘Flavours’ of additive manufacturing Stereolithography (photopolymerisation) • Uses UV to photopolymerise a liquid resin. • Plastics/ceramics Laser Sintering • Metallic or ceramic • A laser is used to fuse a powder material Fused deposition modelling – a.k.a. 3D printing Additive manufacturing (AM) Generic process 1. CAD Computer aided design of the object 2. STL conversion STL is the generic file format for AM 3. Transfer to machine Orientation the object on the build platform 4. Machine set-up Ensuring correct print material etc. 5. Build Sit back - relax 6. Remove The build plate is removed, heat treatment, object removed 7. Post-process Machine, polish, coat, paint etc. 8. Application Finish Presentation outline Introduction Additive manufacturing of optics Additive manufacturing of X-ray optics Research plan Summary and conclusion Additive manufacturing of optics Case study 1: Harrison Herzog et al., ‘Optical fabrication of lightweighted 3D printed mirrors’, Proc. Of SPIE 9573, 957308, (2015) University of Arizona, USA Aluminium rms roughness = 22nm Titanium = optical surface not achieved Additive manufacturing of optics Case study 2: Michael Sweeney et al. ‘Application and Testing of Additive Manufacturing for Mirrors and Precision Structures’, Proc. Of SPIE 9574, 957406, (2015) General Dynamics – Global Imagining Technologies, USA Before: PV = ~500nm rms = ~70nm After: PV = ~300nm rms = ~40nm Additive manufacturing of optics Case study 3: Junjie Luo et al. ‘Additive manufacturing of glass for optical applications’, Proc. Of SPIE 9738, 97380Y, (2016) Missouri University of Science and Technology, USA Presentation outline Introduction Additive manufacturing of optics Additive manufacturing of X-ray optics Research plan Summary and conclusion Motivation 1 of 4 proposals being studied by NASA for the 2020 decadal. Design based upon Chandra heritage. If selected at the 2020 decadal, assuming all goes well, launch around 2030s/2040s. Tapping into existing technology Technology void X-ray Surveyor NASA led Trying not to reinvent the wheel Looking at where there is investment in technology. Where is relevant research currently taking place? X-ray Surveyor: R&D today polishing thin shells Static correction methods Monocrystalline silicon X-ray mirrors Active correction methods Mirror surface Slicing Etching X-ray Surveyor: R&D today ? Static correction methods Monocrystalline silicon X-ray mirrors Mirror surface Slicing Etching Active correction methods Additive manufacturing X-ray optics: concept 1. Design The CAD design of the optic and lightweighting converted to STL and orientated with in the machine Concept 2. Print Press GO! It could be printed via a variety of materials and methods. Concept 3. Post-process Post processing is required! • Heat treatment to reduce stress • Removal from build base • Post-machining 4. Polish The machined surface could then be ground and polished to the desired optical prescription Additive manufacturing X-ray optics: why? Notational X-ray surveyor requirements Taken from a talk by M. Schattenburg 2016 Max. diameter 3-5m Focal length 10-20m On axis HPD (@ 1keV) 0.5 arc-sec Design Wolter-Schwartzshild FOV diameter (<1 arc sec) 15 arc-min Mirror shells ~300 # Mirrors (segmented design) 10,000-50,000 Effective area @ 1keV (mirror) ~2-3 m2 Nominal bandwidth 0.1-10 keV Direct polishing has historically always provided the means to achieve high resolution X-ray optics Additive manufacturing is well placed for batch production without requiring custom machinery. The use of robotic polishing machine will also speed up production once a process has been developed. Other advantages • Reduction in manufacturing steps. • A ready ability to light-weight without waste material • Integration of a support structure with the optical component and therefore minimising mounting and CTE (coefficient of thermal expansion) mismatch problems. • Cost and time How thin and light-weight can additive manufacturing go? Presentation outline Introduction Additive manufacturing of optics Additive manufacturing of X-ray optics Research plan Summary and conclusion Research Plan 2 year fellowship • Start: Aug 2016, end: July 2018 • Objective: experimental combined with simulations (FEA, ray tracing) • Current status: forming collaborations and applying for funding Funding 1 (6 months)* Funding 2 (12 months)* Aug 2016 Jul 2018 Build collaborations Apply for funding Investigation – materials, polishing etc. Prototype design and build X-ray testing? * if successful Research Plan: investigation Investigation – materials, polishing etc. Experimental Produce small flat circular test samples out of a variety of materials and methods to evaluate suitability. Theoretical Use finite element analysis (FEA) to optimise the light-weighting structure to ensure maximum rigidity for minimum mass. Pass the FEA to ray tracing to determine the effects of light-weighting print-though on the optical surface. • Small flat test samples • ~40mm in diameter and 5mm thick. • Light-weighted • Polished • Metrology Research Plan: prototypes Prototype design and build The design and fabrication of the prototype will be determined after the initial samples. Concept It is expected to be a segment of a full shell. It will be designed to be X-ray tested. Directly polished Concept Prototype mandate: • Thinner than Chandra’s optics - probably 5 – 2mm. • Significantly lighter than Chandra. Aiming for a areal density of ~8kg/m2 (X-ray Surveyor ~ 2kg/m2) Other applications Not just astronomical X-ray optics…. Optical, IR and Earth Observation: Design for Demise (ESA) • Space debris mitigation can be achieved through designing a satellite to ‘demise’ within the Earth’s atmosphere. • Current optical components made from glass or ceramic do not readily burn up in the Earth’s atmosphere. • Light-weighted additive manufactured optics could potentially offer an alternative (image credit: ESA I would like to credit Prof. Peter Doel at UCL for pointing me in this direction Synchrotron optics • Integration of support structures to minimise mounting effects. • Embedding a cooling system within the optic to remove the requirement of mounting a cooling system to the optic I will be working with the Diamond Light Source to this end Presentation outline Introduction Additive manufacturing of optics Additive manufacturing of X-ray optics Research plan Summary and conclusion Summary: technology development “Golden Quadrant” Current R&D at various TRL levels for X-ray Surveyor Direct polishing Monocrystalline Si Static correction Active correction Summary: fellowship project “Golden Quadrant” Current R&D at various TRL levels for X-ray Surveyor Direct polishing Monocrystalline Si Static correction Additive manufacturing of astronomical components – with emphasis on optics and the X-ray domain. Goal: To design and build some X-ray reflecting prototypes that show potential for a golden quadrant future X-ray telescope. Active correction Summary and conclusion 1. Introduction to fellowship scheme and additive manufacturing. 2. Outlined existing developments in additively manufactured optics. 3. Discussed the motivation and why additive manufacturing is an interesting and viable fabrication method to study. 4. Outlined my research plan for the next 2 years 5. Discussed other applications Acknowledgements This project has received funding from the European Union’s Horizon 2020 research and innovation programme under the Marie Skłodowska-Curie grant agreement No. 665593 awarded to the Science and Technology Facilities Council. I also acknowledge the UKATC for supplying the non-EU part of the Fellowship Many thanks to all my collaborators/peers would have provided useful insight on this project: • University of Leicester • University College London • Daresbury Laboratory • The Diamond Light Source Thank you for your attention!