Integrated CAD/CAM Process for Cost-Effective Flexible Manufacturing of High-Performance X-ray Optics

Polycapillary x-ray monolithic optics have the potential to be one of the best methods for controlling x-ray beams across a broad energy spectrum because of their efficiency, size, and applicability to a variety of technologies. Widespread use of polycapillary optics is currently impeded because after the design stage, the first working prototype may take a month or more of manufacturing effort. Consequently, both the need and the opportunity exists to develop a comprehensive approach to lens production by computer aided design/computer aided manufacture (CAD/CAM). In this Phase I proposal, we will demonstrate the feasibility of controlling the polycapillary lens manufacturing process from design to product by testing and evaluating the critical parameters and developing an approach for real-time computer process control. The work is expected to lead to a process that will condense the production cycle time to one hour. Our expert team of scientists, progrannners and engineers have the key skill set to develop this innovation in automated manufacture of polycapillary optics. Furthermore, as the design-to-product time decreases, the responsiveness and cost effectiveness for single optic and batch production runs for research, medical, military, and industrial applications would dramatically improve. The radically shortened production schedule for advanced technology, polycapillary x-ray optics will directly effect US competitiveness through the sale of optics, and more importantly, the sale of competitively superior x-ray based instruments.