The Fraunhofer Institute for Applied Optics and Precision Engineering (IOF) uses SLM 3D printing technology to reduce the weight of scanning mirrors and space telescopes by 75%. The lens will be on display at Photonics West in San Francisco next week.
At this year's Photonics West show in California, the German research institute Fraunhofer IOF will showcase a range of quantization and additive manufacturing technologies. The Jena-based research facility will showcase a range of innovative laser-based technologies, including 3D printed scanning mirrors and space telescopes, which are 75% lighter than traditional products.
Fraunhofer IOF's team of experts uses Selective Laser Melting to make these ultra-light metal mirrors. Thanks to lightweight design including random and symmetrical structures, materials such as AlSi12, AlSi40 and Al6061 can be used to achieve weight reductions of up to 75%, all of which are now available for 3D printing.
This has greatly reduced the weight of the metal mirror, but the Fraunhofer IOF is not the first to make incredible lightweight metal optics. For many years, the Institute has used tools such as diamond tools and cutting technology to convert aluminum into lightweight structures. But the range of these methods is limited: the substrate geometry is limited, which means that only a certain simple shape can be formed.
This range is significantly expanded by 3D printing. Fraunhofer IOF uses SLM 3D printers to create complex parts of metal powder and is constantly trying to incorporate new materials into the process.
In a recent study, the study found that hypereutectic aluminum silicon works well as a 3D printed material with a very high cooling rate that can be used for the fusion of powder particles. It is said that the mechanical properties obtained are comparable or better than those of conventional alloys of the same chemical composition, while the fine microstructure has a porosity of less than 0.05%.
However, 3D printed lenses can reduce weight. Fraunhofer IOF engineers can do this by generating the unit structure of the rules, the rules or irregular grids, the topology optimization design, and the simulation of the running structure methods.
This means that some unnecessary parts of the structure are simply excluded. The inner area of ​​the lens is an area that has no direct effect on the stability of the structure, and can be reduced in weight by reducing the density.
Although the printer does not generate a ready-to-use lens. After 3D printing of these lightweight structures using an SLM printer, they are post-processed using other techniques to achieve high levels of optical precision. Fraunhofer IOF indicates that after this post-treatment step, a 150 mm mirror has "high stability and stiffness" and a surface roughness of <1 nm RMS and a deviation of <150 nm PV.
It is reported that Photonics West will welcome about 20,000 visitors, and will have the opportunity to watch more than 5,200 speeches and more than 1,300 exhibitors. In addition, visitors will be able to see other exciting innovations from the Fraunhofer IOF, including its new AR-plas2 technology, which produces organic nanostructures for broadband antireflection coatings for the preparation and measurement of photons and atoms. Quantum mechanical properties of laser technology and so on.
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