Outpost Technologies, the CAO, and EO Solutions shall produce UV-class flat optical mirrors meeting the requirements above using proven flight-heritage material, machining, polishing, and coating processes. Aluminum metal matrix composites (AlMMCs) have unique material properties that provide both mechanically and thermally stable substrates for mirror systems, especially in harsh launch and thermally volatile environments. Materions SupremEX alloys are superior to aluminum in their mechanical performance. SupremEX 640XA has almost twice the specific stiffness of aluminum and other traditional aerospace metals due to the 40% SiC content by volume. The SiC content not only improves mechanical performance, wear resistance, strength, and vibration survivability, but also reduces the CTE to near identical that of nickel. Nickel is easily diamond turned, polished, and coated for a wide range of EM spectrum applications. SupremEX and other AlMMCs are traditionally machinable on manual or CNC machining platforms unlike glass and composites which require diamond cutting/grinding, cost-intensive molds, bonding processes, casting, curing and process validations. The material is also readily available from domestic sources. The SupremEX material properties trade exceptionally well in optical applications. Therefore, Outpost Technologies is continuing to improve manufacturing and design methods with AlMMCs to prove viability for space optical applications. SupremEX is commercially available in billets, forgings, extrusions, plates, sheets, foils, and precision machined components, some of which are controlled by AMS standards. The proposed mirror deliverables will include five (5) total 25.4 mm x 6 mm thick (1.00 x 0.25 ) flat mirror discs for the Phase I Base effort and three (3) total 76 mm x 9.5 mm thick (3.00 x 0.375 ) lightweighted mirrors for the Phase I option. All mirrors stock and machine tooling have already been purchased and are in stock at Outpost Technologies. This Phase I effort is hardware driven, aiming to prove technical capability, and cost benefits of AlMMC materials for small sat UV mirror applications versus conventional aluminum, glass, and composite materials. Outpost and its partners will focus is to provide a lightweight, highly precise solution, which validates the use of this material specifically for UV/VUV spectrum application. The proposed solution meets the specifications listed in Table 1. This material and application technology currently reside at TRL 3 with multiple proof of concept studies, analyses and experiments completed. During the 12-month period of performance, Outpost Technologies will design and manufacture two (2) flat mirror designs. This demonstration would meet TRL 5 maturity by proving basic functionality, identifying technical benefits, correlating analytical data to prototype testing, and identifying improvements for more complex geometry manufacturing.
Benefit: Fast steering mirrors (FSMs) are a critical component in a variety of applications such as laser beam control, optical communications, and astronomy. To successfully commercialize FSMs, a multi-faceted strategy should be implemented. Firstly, it is essential to conduct market research to identify potential customers and their requirements. Secondly, partnerships with key players in the industry should be established to develop customized solutions for specific applications. Thirdly, an effective marketing campaign should be implemented to raise awareness and educate potential customers about the benefits of using FSMs. Fourthly, the development of a robust distribution network should be prioritized to ensure easy availability of the products. Lastly, continuous research and development efforts should be carried out to improve the product and stay ahead of the competition. By implementing this strategy, FSMs can be successfully commercialized, and the product can be positioned as a leading solution in the industry. One of the key competitive advantages of an aluminum composite FSM substrate is its lightweight yet durable nature. The use of aluminum as a base material provides high strength-to-weight ratio, making it ideal for applications that require fast and precise movements. Additionally, the composite material is corrosion-resistant, ensuring the longevity of the substrate and reducing the need for frequent replacements. The aluminum composite substrate also offers superior thermal stability, maintaining its shape and stability under extreme temperatures, which is critical for applications that involve high-power lasers. Moreover, the use of this substrate enables the production of FSMs at a lower cost compared to traditional materials, allowing for wider adoption and increased affordability for potential customers. Overall, the use of aluminum composite FSM substrate offers a range of competitive advantages, making it an attractive choice for commercialization. Lastly, directed energy and counter-unmanned aircraft systems (C-UAS) also require rugged, low-cost optics capable to perform in extreme heat loads and thermal environments. Outpost, EO Solutions, and the CAO work in these industries and have direct contact with C-UAS customers through existing government prime and subcontracts. Applications are readily available to broaden current engineering design and analysis scopes through open OTA and OASIS contracts. All team members will work with their respective customers (mostly Army and Air Force) to identify current needs in C-UAS programs and market the thermally stable, lightweight, and rugged AlMMC optics.
Keywords: advanced manufacturing, advanced manufacturing, cubesat, Optics, Aluminum Metal Matrix Composites, UV Mirrors
