Extremely Low Areal Density Composite Isogrid Supported Hybrid Membrane Optical Shell Reflector

Mevicon Inc., ManTech-SRS, and Foster-Miller, leading innovators in the area of lightweight Membrane Optical Systems, materials, and structures have teamed to propose the development of a novel and innovative method of realizing very low areal density, cost effective membrane reflectors based on a combination of 1) Mevicon Inc’s demonstrated scalable, cost efficient fabrication approach for “Strength Through CurvatureTM” enabled single surface membrane shells, 2) SRS’s low CTE optical grade membrane polyimide materials and coatings (1.5 nm rms surface roughness, ë/20 thickness variation over 10 cm+ samples), 3) Foster-Miller’s extremely lightweight CHIM isogrid boundary support structure technology, and 4) a range of Mevicon’s proven figure control techniques. Phase I results show that this combination yields extremely low areal density reflective mirror surfaces and boundary support structures, leading to significant reduction of downstream system performance requirements and hence cost for space and eventually terrestrial reflective optical systems of interest to the AF and DoD. In the PII we propose to continue to demonstrate the combination of the four areas, continue to refine membrane reflector production global figure authority and quantify readiness for flight and performance trends. This prepares the way for potential PIII transition opportunities. BENEFIT: The proposed innovation has strong promise to yield an extremely cost efficient, and extremely low areal density optical reflector technology. As such it would find direct applications in a range of space based optical systems in application areas of interest for the AF, DoD, and other Government organizations in the area of earth and deep space situational awareness/observation, space weather monitoring, space science and astronomy. The same basic lightweight aperture technology could also be directly applied to a range of coherent and incoherent LIDAR and LADAR applications as well as optical elements of LaserComm terminals. With additional research into promising coating techniques, directed energy applications are foreseen as well. While the delta in terms of areal density advantage are greatest at optical wavelengths, multiple additional application areas exist for longer wavelength applications in the Near and Far IR, THz, microwave, and RF wavebands. There are also potential applications as solar concentrators for use in power generation (either solar dynamic or concentrated Photovoltaic) and future space orbital propulsion (solar thermal propulsion or solar sails) applications. Optically powered fast steering mirrors/chopper and eventually low order adaptive optics actuators (i.e. deformable mirrors or even active primaries) are also envisioned. Terrestrially, the biggest return on development is expected in the area of optical apertures for prosumer amateur astronomy, university level 1-2 m telescopes, and as secondaries for professional astronomy telescopes. As fabrication costs come down, applications are anticipated in transportable backcountry emergency apertures for commercial telecom, back-packable solar concentrators for water heating, distillation and cooking. Military applications in lightweight spotting, and laser designating scopes are foreseen as well.