Mr. Michael Harris Profile

Michael Harris

at STFC Rutherford Appleton Lab

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Author

Publications (5)

Proceedings Article | 4 October 2023 Presentation + Paper

Understanding the role of additive manufacturing in the development of astronomical hardware

Carolyn Atkins, Younes Chahid, James Wells, Marcell Westsik, Katherine Morris, Ciarán Breen, Alastair Macleod, Lawrence Bissell, William Cochrane, Richard Kotlewski, Scott McPhee, Robert Snell, Iain Todd, Mat Beardsley, Michael Harris, Misael Pimentel, Scott McKegney, Jonathan Orr, Simon Alcock, Ioana Theodora Nistea, Simone Cottarelli, Samuel Tammas-Williams

Proceedings Volume 12677, 126770L (2023) https://doi.org/10.1117/12.2677452

KEYWORDS: Design and modelling, Lightweight mirrors, Porosity, Astronomy, Aluminum, Single point diamond turning, Prototyping, Optics manufacturing, Additive manufacturing, 3D printing, Optomechanical components, Astronomical instrumentation engineering, Aluminum mirrors

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Proceedings Article | 4 October 2023 Presentation + Paper

From design to evaluation of an additively manufactured, lightweight, deployable mirror for Earth observation

Marcell Westsik, James Wells, Younes Chahid, Katherine Morris, Maria Milanova, Mat Beardsley, Michael Harris, Lucas Ward, Simon Alcock, Ioana-Theodora Nistea, Simone Cottarelli, Samuel Tammas-Williams, Carolyn Atkins

Proceedings Volume 12677, 1267704 (2023) https://doi.org/10.1117/12.2677303

KEYWORDS: Prototyping, Design and modelling, Single point diamond turning, Optical surfaces, Porosity, Simulations, Mirrors, Mirror surfaces, 3D printing, Additive manufacturing

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Proceedings Article | 29 August 2022 Presentation + Paper

Towards understanding and eliminating defects in additively manufactured CubeSat mirrors

Robert Snell, Carolyn Atkins, Hermine Schnetler, Younes Chahid, Mat Beardsley, Michael Harris, Chenxi Zhang, Richard Pears, Ben Thomas, Henry Saunders, Alexander Sloane, George Maddison, Iain Todd

Proceedings Volume 12188, 121880V (2022) https://doi.org/10.1117/12.2629935

KEYWORDS: Mirrors, Additive manufacturing, Surface finishing, Aluminum, Polishing, Optics manufacturing, Manufacturing, Solids, Laser energy

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Proceedings Article | 13 December 2020 Presentation + Paper

An additive manufactured CubeSat mirror incorporating a novel circular lattice

Robert Snell, Carolyn Atkins, Hermine Schnetler, Iain Todd, Everth Hernández-Nava, Alistair Lyle, George Maddison, Katherine Morris, Christopher Miller, Mélanie Roulet, Emmanuel Hugot, Fabio Tenegi Sanginés, Afrodisio Vega-Moreno, L. T. G. (Bart) van de Vorst, Joris Dufils, Leon Brouwers, Szigfrid Farkas, György Mező, Mat Beardsley, Michael Harris

Proceedings Volume 11451, 114510C (2020) https://doi.org/10.1117/12.2562738

KEYWORDS: Mirrors, Additive manufacturing, Prototyping, Interferometry, 3D printing, Telescopes, Interfaces, Silicon, Aluminum, Single point diamond turning

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Proceedings Article | 10 July 2018 Presentation + Paper

Topological design of lightweight additively manufactured mirrors for space

Carolyn Atkins, Charlotte Feldman, David Brooks, Stephen Watson, William Cochrane, Melanie Roulet, Emmanuel Hugot, Mat Beardsley, Michael Harris, Christopher Spindloe, Simon Alcock, Ioana-Theodora Nistea, Christian Morawe, François Perrin

Proceedings Volume 10706, 107060I (2018) https://doi.org/10.1117/12.2313353

KEYWORDS: Mirrors, Polishing, Surface roughness, Additive manufacturing, Finite element methods, Space mirrors, Aluminum, Single point diamond turning, Lightweight mirrors, Error analysis, 3D printing

Read Abstract +

Additive manufacturing (AM), more commonly known as 3D printing, is a commercially established technology for rapid prototyping and fabrication of bespoke intricate parts. To date, research quality mirror prototypes are being trialled using additive manufacturing, where a high quality reflective surface is created in a post-processing step. One advantage of additive manufacturing for mirror fabrication is the ease to lightweight the structure: the design is no longer confined by traditional machining (mill, drill and lathe) and optimised/innovative structures can be used. The end applications of lightweight AM mirrors are broad; the motivation behind this research is low mass mirrors for space-based astronomical or Earth Observation imaging. An example of a potential application could be within nano-satellites, where volume and mass limits are critical. The research presented in this paper highlights the early stage experimental development in AM mirrors and the future innovative designs which could be applied using AM.

The surface roughness on a diamond-turned AM aluminium (AlSi₁₀Mg) mirror is presented which demonstrates the ability to achieve an average roughness of ~3.6nm root mean square (RMS) measured over a 3 x 3 grid. A Fourier transform of the roughness data is shown which deconvolves the roughness into contributions from the diamond-turning tooling and the AM build layers. In addition, two nickel phosphorus (NiP) coated AlSi₁₀Mg AM mirrors are compared in terms of surface form error; one mirror has a generic sandwich lightweight design at 44% the mass of a solid equivalent, prior to coating and the second mirror was lightweighted further using the finite element analysis tool topology optimisation. The surface form error indicates an improvement in peak-to-valley (PV) from 323nm to 204nm and in RMS from 83nm to 31nm for the generic and optimised lightweighting respectively while demonstrating a weight reduction between the samples of 18%. The paper concludes with a discussion of the breadth of AM design that could be applied to mirror lightweighting in the future, in particular, topology optimisation, tessellating polyhedrons and Voronoi cells are presented.

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