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In this paper we demonstrate two approaches for optimising flexure geometry to follow arbitrary focal surface curvature and to orient the optical fibre with arbitrary tilt. These approaches are: analytical using MATLAB models and FEA based using Ansys. The approaches are complementary allowing the designer to efficiently explore the parameter space and then do precise optimisation of the flexure geometry. We demonstrate the applicability both to the UKATC’s preferred design for WST, and to flexure-based fibre positioner designs generally. We also present a sensitivity analysis relating small changes in design parameters to changes in fibre tip motion. Finally we briefly present the UKATC's preferred geometry for the WST fibre positioner.
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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