Abstract

The high-performance, lightweight Be mirrors for use on space systems that will be operational in the 21st century are being conceived, designed, and prototyped now. This paper explains the integrated set of processes, techniques, and technologies in use today at Hughes Danbury Optical Systems (HDOS) to produce lightweight, closed-back, aspheric mirrors from near-net-shaped hot isostatic pressed substrates. The process starts from scratch with two givens: mirror performance specification and Be powder. The specifications drive the design of the mirror substrate and determine the internal geometries and tooling required to incorporate the optimal radius into the as-HIP'ed, near-net-shaped blank. The patented technique for configuring the internal tooling to accomplish this is presented, as are the stringent controls implemented during the powder loading, sealing, outgassing, hipping, decanning, and machining operations. The optical-finishing technologies from controlled grind/etch through superpolish are described, along with the metrology systems for validating that the requirements are met. The processes, techniques, and technologies are illustrated through actual aspheric mirrors built by HDOS. These mirrors are directly applicable to space applications in the 21st century.

© 1990 Optical Society of America