Monolithic Dual-Axis Mirror Structure for Low-Wavefront Steering
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Solution Overview
Problem
Existing fast steering mirrors with flexure type gimbals face issues of fragility, limited size and load options, and disparate materials with different thermal expansion coefficients, leading to wavefront errors and the need for multiple parts assembly with bonding processes.
Innovation Solution
A monolithic dual axis mirror system is fabricated using additive and subtractive manufacturing processes, integrating the gimbal and flexure features as a single unit without joining elements, allowing for customizable stiffness and reduced damage risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple parts are assembled through bonding processes, then the mirror system can be constructed with available commercial components, but the assembly complexity increases and structural stiffness decreases
Solution Approach 1:
The patent merges the gimbal and mirror into a single monolithic structure fabricated from one piece of material using additive manufacturing. This eliminates the need for bonding multiple commercial components together, reducing assembly complexity while maintaining manufacturing feasibility through modern fabrication techniques.
2Ease of manufacture
If multiple parts are assembled through bonding processes, then commercial components can be used, but the structural stiffness and reliability deteriorate
Solution Approach 1:
The gimbal and mirror are combined into a monolithic structure that eliminates bonding interfaces, thereby improving structural stiffness and reliability. The single-piece construction removes weak points at bond lines while maintaining ease of manufacture through additive fabrication processes.
3Adaptability or versatility
If disparate materials with different CTE values are used, then design flexibility increases, but wavefront errors increase due to thermal expansion mismatch
Solution Approach 1:
The patent uses a homogeneous material for both the gimbal and mirror components, ensuring matching thermal expansion coefficients. This eliminates wavefront errors caused by thermal expansion mismatch while maintaining design flexibility through the monolithic structure's inherent adaptability.
4Reliability
If fragile gimbal components are used, then low friction and high repeatability are achieved, but the reliability and ease of handling deteriorate
Solution Approach 1:
The fragile gimbal components are merged into a robust monolithic structure that maintains the low-friction, high-repeatability characteristics while improving ease of handling. The integrated design eliminates separate fragile parts that require careful handling during assembly and operation.
Data Source
AI summary
A method includes fabricating a mirror system that includes a dual axis gimbal, a mirror, and a mirror substrate that are formed together as an integral component using an additive manufacturing process. The method also includes forming multiple first gaps in the mirror system using a subtractive manufacturing process, where the first gaps extend through the mirror system in a first direction. The method further includes forming multiple second gaps in the mirror system using the subtractive manufacturing process, where the second gaps extend through the mirror system in a second direction perpendicular to the first direction. The first gaps and the second gaps separate the gimbal into a top portion and a bottom portion.