3D Printed Silicon Carbide Scalable to Meter-Class Segments for Far-Infrared Surveyor

Using technology spun out from Sandia National Laboratories, Goodman Technologies LLC with our Small Business and Minority Serving Institution partner(Team GT) has demonstrated the feasibility of 3D printed and additively manufactured SiC/SiC composite and Reaction Bonded SiC for low areal cost, ultra-lightweight mirrors and structures. Our technology development roadmap shows production of the first meter-class mirror segments in time for the 2020 Decadal Survey, and an excellent solution for multiple Priority 1, 2 and 3 Technology Gaps identified in the COR 2016 and 2017 PATRs. Our meter-class 3d/AM silicon carbide segments will meet or exceed all NASA requirements for the primary mirror of a FIR Surveyor such as the Origins Space Telescope (OST), and may also provide a solution for the LUVOIR Surveyor. During Phase II we achieved an areal density of 10 kg/square meter on our first attempt at a production rate of 1.44 square meter per day for a single small printer. Acost of $60K to 3D print/AM large segments looks readily achievable, as does an optical surface that has nanometer-scale tolerances. Our encapsulated lattice construction provides a uniform CTE throughout the part for dimensional stability, incredible specific stiffness, and the added benefit of cryo-damping. Our process will also allow for direct embedding of electronics for active structures and segments, and the potential for actively cooling with helium for unprecedented low emissivity and thermal control. Finally, the particulate paste extrusion process may be very suitable for printing mirrors in the zero gravity of space.During Phase II, we propose to optimize, mature and scale 3D printed silicon carbide mirrors and telescope structures traceable to OST and LUVOIR Surveyors through the demonstration of Pathfinder Surrogate components for a meter-class primary mirror for the NASA Gondola for High Altitude Planetary Science (GHAPS) project.