Many missions in space and sub-orbital atmosphere require lightweight telescope systems for imaging applications. The planned New Horizons Mission to Pluto is such an example that requires a lightweight telescope system. The NASA's Next Generation X-ray Optics (NGXO) project is an example of a need for a lightweight x-ray mirror system. Balloon missions are a specific application that would be perfect for lightweighted 3D printed mirrors. Balloon missions are highly recommended for next generation observatories. Additionally, the Astro2010 report identified that lightweight mirrors for both x-ray and UV/Visible applications are necessary for several different future missions. A lightweighted 3D printed optic could dramatically change the design space for the mirror in these missions.
Mirror-coated 3D printed optics can be used for airborne laser systems. Firing an airborne laser is significantly cheaper than firing an anti-missile missile. In addition, there is no recoil or after effect. However, to make airborne power lasers realizable to many applications, a weight reduction of the laser system is required. A reduction in weight increases the available time in flight as well as improves the speed and accuracy of tracking. It has been estimated that the optical assembly may comprise 40-50% of the total weight of the laser system. Thus, a significant opportunity exists to advance airborne lasers by reducing the weight of the optical assembly. Freeform optics are quickly becoming part of many commercial and military optical systems. Many optical designers are starting to use freeform optics to achieve optical performance (less aberrations), lighter weight optical systems through a reduced number of components, and an increased ability to go off axis with smaller and tighter packages. Optimax is starting to offer commercial quality freeforms as a standard component. We are seeing designs for beam shaping, corrector plates, conformal windows, and head-up displays for example. 3D printing of mirror substrates for freeform optics would expand the design space possible.
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