Composite Replica Mirrors for Lightweight Space Optics

Cornerstone Research Group, Inc., proposes to develop a multi-component composite material system and replica mirror fabrication technology which will address the drawbacks of conventional materials and fabrication processes for space-based mirrors.Completing development of materials demonstrated feasible in Phase I, this project will demonstrate mature multi-component composite materials optimized for application in lightweight replica mirrors for space-based imaging systems. The resultingmaterials (both organic and inorganic composites) will provide major reduction in mirror areal density (compared with current operational mirrors) while achieving strength, stiffness, and thermal properties required for space applications. Completingdevelopment of fabrication technology demonstrated feasible in Phase I, this project also will implement an operationally relevant prototype demonstration of composite replica mirror production. In this revolutionary approach to mirror fabrication,composite replicas are cast from an optical quality master mold. This dramatically simplifies the mirror fabrication process, thereby enabling less expensive tooling than conventional practice for glass or metal mirrors. Further, in production lots ofidentical mirrors (e.g., for constellation spacecraft systems), the replication approach to fabrication will provide radical reduction in mirror costs by eliminating the lengthy, expensive grinding and polishing processes for individual units.