Lightweight and High-Stiffness Metal Optical Systems Based on Additive Manufacturing

Abstract

To build a long-wave infrared catadioptric optical system for deep space low-temperature target detection with a lightweight and wide field of view, this work conducted a study that encompasses a local cooling optical system, topology optimization-based metal mirror design, and additive manufacturing. First, a compact catadioptric optical system with local cooling was designed. This system features a 55 mm aperture, a 110 mm focal length, and a 4-degree by 4-degree field of view. Secondly, we applied the principles of topology optimization to design the primary mirror assembly, the secondary mirror assembly, and the connecting baffle. The third and fourth modes achieved a resonance frequency of 1213.7 Hz. Then, we manufactured the mirror assemblies using additive manufacturing and single-point diamond turning, followed by the centering assembly method to complete the optical assembly. Lastly, we conducted performance testing on the system, with the test results revealing that the modulation transfer function (MTF) curves of the optical system reached the diffraction limit across the entire field of view. Remarkably, the system’s weight was reduced to a mere 96.04 g. The use of additive manufacturing proves to be an effective means of enhancing optical system performance.