Lightweight Glass Optics with Fused Layered Core Structures
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Solution Overview
Problem
Conventional manufacturing techniques for lightweight glass optics, such as mirror substrates, struggle to create small, intricate features due to the fragility of glass and limitations in subtractive processes, which are inefficient for complex geometries.
Innovation Solution
A method involving additive manufacturing where glass powder is deposited and fused onto a contoured facesheet to form a core material structure, allowing for the creation of a mirror substrate with optimal three-dimensional topology, varying material properties in successive layers, and using a facesheet as part of the finished product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If subtractive manufacturing processes (milling, grinding, polishing) are used to create lightweight glass optics, then a stiff and stable glass structure with precisely shaped optical surface can be achieved, but the ability to manufacture small intricate features is limited due to glass fragility
Solution Approach 1:
The patent changes the fundamental manufacturing parameter from subtractive removal to additive deposition. Glass powder is deposited layer-by-layer and fused to build complex three-dimensional structures that would be impossible to achieve through subtractive processes on fragile glass substrates
Solution Approach 2:
The patent creates a composite structure where a contoured glass facesheet (providing optical precision) is combined with a additively manufactured core structure (providing intricate geometry). This composite approach allows each component to fulfill its specific functional requirements
2Manufacturing precision
If conventional subtractive processes are used to manufacture lightweight glass optics, then a precisely shaped optical surface can be achieved, but the manufacturing time and efficiency are insufficient for complex geometries
Solution Approach 1:
The contoured facesheet is pre-formed with the required optical surface geometry before the additive manufacturing process begins. This preliminary preparation allows the subsequent additive process to focus solely on building the core structure, significantly reducing total manufacturing time
Solution Approach 2:
The patent transitions from two-dimensional surface processing to three-dimensional additive construction. By building the core structure in layers with varying material properties and geometries, complex three-dimensional features are manufactured efficiently without the time constraints of conventional subtractive methods
3Device complexity
If additive manufacturing is used to create intricate glass features, then small complex features can be manufactured, but thermal stress issues arise during the fusing process
Solution Approach 1:
The patent applies local quality by using a contoured facesheet with specific geometric features designed to manage thermal stress distribution. The non-uniform thickness and curvature of the facesheet create stress-relief zones that prevent thermal cracking during the additive manufacturing process
Solution Approach 2:
The contoured facesheet acts as an intermediary element between the build plate and the additively manufactured core structure. It serves as a thermal buffer that mediates heat transfer, reducing thermal gradients and stress accumulation in the fragile glass powder layers during fusing
4Weight of moving object
If glass powder is successively fused to build core material structure, then optimal three-dimensional topology with minimal mass can be achieved, but the process requires precise control of material properties in successive layers
Solution Approach 1:
The patent implements local quality by varying material properties (such as glass composition, particle size, or density) in different layers or regions of the core structure. This allows optimization of each layer's properties for its specific structural role, achieving minimal mass while maintaining required stiffness and stability
Solution Approach 2:
The manufacturing process is made dynamic by allowing material properties to change progressively through successive layers. The system adapts material characteristics layer-by-layer based on the evolving structural requirements, enabling precise control over the final component's mechanical and thermal properties
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the production of optical components with intricate features, minimal mass, and required stiffness and stability, while overcoming thermal stress issues of conventional methods, enabling larger and quicker fabrication of glass optics.
Implementation Method 1
Fusing glass powder material can include fusing low expansion glass powder into low expansion glass, e.g., with a laser
Implementation Method 2
Fusing glass powder material can include fusing low expansion titania-silica glass powder into low expansion titania-silica glass
Data Source
AI summary
A method of forming an optical component includes depositing slurry that includes glass powder material onto a facesheet and fusing the glass powder material to a facesheet to form a first core material layer on the facesheet. The method also includes successively fusing glass powder material in a plurality of additional core material layers to build a core material structure on the facesheet. The method can include selectively depositing slurry including glass powder material over only a portion of at least one of the facesheet, the first core material layer, and/or the one of the additional core material layers. Depositing the slurry can include extruding the slurry from an extruder.