1638 S. Research Loop, # 100Tucson, Arizona 85710(520) 733-9302 Ph.(520) 733-9306 Faxhttp://www.compositemirrors.com

Composite Mirror ApplicationsCompany Statement: May 2012

• Mission Statement:Apply 20+ years of experience in prototype design and fabrication of CFRP optical mirrors and structures and apply to manufacturing products for a host of commercial and government applications.

CMA’s transition into manufacturing is encouraged by offering products for the optical markets which are lighter weight, faster to produce and less expensive than virtually all other competing materials.

Primary Focus

• Core Competencies:Design, prototype and manufacture unique custom high-quality lightweight optics and optical systems from Carbon Composite Materials. Activity supported by ongoing R&D through SBIR, NRA, BAA and IRAD.

•Mirror fabrication process design and development •Unique and challenging optical mirror design and fabrication•Prototyping of various optics and structures from CFRP•Optical reflective coatings•Vertically integrated•Proficiency in long-wave thru visible wavelength applications

Core Competency

Key Personnel• Robert Romeo, President, Aerospace/Materials /Composites Engineer• Dr. Robert Martin, Director of Engineering and Programs, Physicist and

Electrical Engineer, 40 years RF Engineering• Wayne Anderson, Composites Engineer, 30 years experience in

aerospace composites.• Doug Riebe, 15 years experience with CFRP mirror and structure

Fabrication, CNC• Jim Telewski, QA Coordinator, Electrical Engineer, Machinist, CNC• Ryan Romeo, Design, Visual Communication, Production Manager• Melissa Redstone, Mechanical Engineer• Adam Williams, Electrical Engineering Technology• Susan Romeo, CFO• 17 total EmployeesCMA, Inc.• Incorporated August 1991 (20 years)• 16,000 ft2 Facility, manufacturing and R&D• Located in Optics Capital, Tucson, AZ

About CMA

NASA Goddard Space Flight Center Naval Post Graduate School

University of Hawaii, Institute for Astronomy Harris Corporation

National Radio Astronomy Observatory Pratt & Whitney Rocketdyne

Air Force Research Lab The Boeing Company

University of Bristol Raytheon, RMS, SAS

Naval Research Laboratory INFN (Italian National Nuclear Facility)

National Science Foundation ASIAA (National Taiwan University)

Vertex Antennentechnik BrightLeaf

Caltech Physical Optics Corporation

QinetiQ ltd. U of A Steward Observatory

Argonne National Laboratory Harvard CFA

Carlo Gavazzi Space ADS/Microgate

Canadian Space Agency FLIR Systems

Jet Propulsion Lab General Dynamics

SAIC Swedish Space Corporation

BrightLeaf Technologies CERN, ESO

Some of Our Customers

CFRP Advantages Basics

• High stiffness/Strength-to-weight Ratio, High resonant frequency

• Low mass, ρ = 1.7 g/cc

• Low Thermal Expansion Coefficient (CTE) < 1 ppm/oC in-plane

• Design Flexibility to tailor stiffness, strength and low CTE where needed.

BASELINE

.05

8.8

2.4

1.0

11.3

22.5

.05

CTE (x10-

6/C)

.77

2.9

84.2

2.6

57.2

69

.04

Thermal Diffusivity

(10-6 m2/sec)

Preferred Value: High

Potential Flight candidate5.243.21465SiC:CVD

Low specific stiffness; Low Thermal diffusivity

2.944.43114Ti 6Al4V

3.29

2.60

5.36

2.93

5.84

Performance Merit*

(E/ρ)1/3

Preferred Value: High

Low specific stiffness8.05141Invar 36

Low CTE imaging mirror material

2.5391Zerodur

Toxicity Issues1.85287Beryllium

~ 2 times heavier than Composite

2.7068Aluminum 6061-T6

Derived from areal density

1.80276Carbon Fiber Reinforced Polymer

NotesDensity

(g/cm3)

Young’s Modulus

(GPa)

Material

* (E/ρρρρ)1/3 Performance merit for minimum self weight deflection on simply supported plate

Stiffness/Strength High Performance Material Comparisons

Material Trades

10

100

1000

1 10

(E/ρρρρ)1/3=5

(E/ρρρρ)1/3=4

(E/ρρρρ)1/3=3

Performance Merit(Self Weight Deflection)

CFRP is design baseline

CFRP Beryllium

Zerodur

Aluminum 6061-T6

SiC:CVD

Ti6Al4V

Invar 36

Youn

g’s

Mod

ulus

(G

Pa)

Density (g/cm3)

Self Weight Deflection Performance Merit

CFRP Advantages Basics

• Design Flexibility to tailor stiffness, strength and low CTE where needed

Applications

UnidirectionalQuasi-isotropic

Directionally Biased Properties

Uniform Properties

Build-to-Print Prototyping in CFRP

Breadboards

Design/Analysis Capability

SolidWorks CADCosmos FEAZEMAX Optical Design

APEX Telescope Subreflector and

Wobbler

Coating/Process Development1.8-meter Vacuum Deposition Chamber

Optical Coatings Vacuum Processes

LVH CoatingChamber

Balzers Coating

ChamberGNB CoatingChamber

EnvironmentalChamber

Cryo-Vacuum Spaceflight Simulation Chamber

• Zygo Mark III Interferometer• HASO 32 Shack-Hartmann wave

front sensor from Imagine Optic, 32X32 array

• WYKO Topo 3-D Surface Measurement

• Fizeau Interferometer• Ronchi Test• Newton Interferometer for up to

60cm diameter

Shack-Hartmann Testing

WYKO Topo 3-DRonchi

Optical Testing

Newton & Fizeau Interferometry

• Process ideal for mass-production of identical optics.

• Mandrel cost is easily amortized with numerous parts.

• Aspheric curves are easily replicated, although figure quality is mandrel dependant.

• Current processes can yield rigid (Passive) CFRP IR mirrors weighing 5 - 10 kg/m2.

CFRP Composite MirrorsTechnology Benefits

What are CFRP Composite Mirrors?

Technology OverviewHigh Accuracy Surface Replication

Finished CFRP Mirror

Mandrel Polishing

Finished Mandrel

CFRP Material

Lay Up Mirror

Lay-Up CFRP Polish/Figure Mandrel

Mandrel

Composite Plies Replica Mirror

Cure and Release

Ready for Coating

Mandrel

Resin layer

Result: NO GRINDING OR POLISHING

REPEATABLE PRODUCTION OF LARGE or SMALL ACCURATE OPTICS

2 Roughness measurements taken from TOPO 3-D, Data showing ~ 8 Angstroms rms directly replicated on CFRP flat from Pyrex mandrel.

CFRP Optical PerformanceRoughness Measurements of Flat CFRP Mirror

1

2

0.36λ P-V @ λ=635nm Wavefront

Ronchigram

CFRP Optical PerformanceShack-Hartmann Wave Front Sensor, 6-inch

CFRP Sphere

Ronchigram

0.55λ P-V @ λ=632nm

CFRP Optical PerformanceShack-Hartmann Wave Front Sensor, 16-inch CFRP Parabola/Cass Primary

f/4 CFRP Parabola 0.22µm P-V wavefront

CFRP Optical PerformanceShack-Hartmann Wave Front Sensor,

16-inch CFRP Parabola/Newtonian Primary

Interferograms at = 633nm of 12-inch CFRP flat mirror, Analysis shows better than /10 p-v across

4 inch diameter section.

CFRP Optical PerformanceEO Performance, Interferograms of CFRP Mirrors

4 inch diameter sub-aperture

Interferograms at = 633nm of 16-inch CFRP parabolic mirror.

Fringes with tilt Null Fringes

Raw Interferograms at = 633nm of 4-inch

CFRP flat mirror for Naval Postgraduate School, Analysis shows /10 p-v across 4 inch diameter.

CFRP Optical PerformanceInterferograms of Flat CFRP Mirrors

4 inch diameter CFRP Flat Mirror

Wavefront Sensor Data at = 635nm, of 3-inch CFRP spherical mirror, analysis shows better than /10 p-v across 3 inch diameter with first 8 Zernike terms removed.

The mirror is only 2mm thick and used as a demonstration for adaptive optics, in collaboration with The University of Arizona s Steward Obs. Mirror Lab.

CFRP Optical PerformanceSurface Data on Spherical CFRP Mirrors for AO

3 inch diameter CFRP Spherical Mirror

CFRP Spherical Mirror mounted to 7-actuator figure control structure

CFRP Optical Performance0.3m, f/1.3 Parabolic Mirror

50 lines per inch Ronchi grating

Image shows highly aspheric figure and some zonal features around the central portion of the mirror.

Note: Ronchi is an excellent tool for qualitative look at the figure of the entire aperture of the mirror. This is a direct look at the mirror without correcting for the aspheric (fringe curvature)

Convex glass mandrels are essential to the production of CFRP mirrors. CMA has a need for various sizes and radii. Shown, left, is our 2m grinding table with a 1m parabolic Pyrex mandrel under fabrication. 1.4m parabola shown below.

Optical FabricationConvex Optical Mandrels

Optical MetrologyConvex Primary Mirror Mandrels

Final Figure

ZEMAX 3-D of the Hindle Null Test for 240-inch ROC parabola

Figure convergence from left to right, bottom of image is the edge of the mandrel

16-inchHindle Test Facility

From R.F. Royce

Hindle Shell R1Hindle Shell R1Hindle Shell R1Hindle Shell R1

Hindle Shell R2Hindle Shell R2Hindle Shell R2Hindle Shell R216161616----inch Parabolainch Parabolainch Parabolainch Parabola

16161616----inch Mountinch Mountinch Mountinch Mount

ULTRA 1m CFRP composite parabolic primary mirror and autocollimation Ronchi image. Autocollimation done over oil flat with the mirror face down , indicates further mandrel figuring is required. The CFRP replica accuracy is limited to the mandrel accuracy.

1-m Parabolic Mirror TestingAutocollimating against oil Flat

Autocollimation Set-up

CFRP Composites Programs

Past And Current Projects

CFRP RICH mirror assembly for University of Bristol, Large Hadron Collider, LHCb experiment at CERN. Themirrors are spherical with an ROC of 2700mm, and areal density of 5 kg/m2, 2 m2 total reflective area, totalweight 36 lbs. Reflectivity optimized for UV @ λ=280nm.

High Energy PhysicsLHCb RICH 1 Mirror Assembly

Back Surface

High Energy PhysicsLHCb RICH 1 Mirror Assembly

(Above) Assembled CFRP RICH 1 Mirrors, (Right) Mirrors final mounted and first results in the RICH 1 experiment at LHCb, CERN

LHCb Industry Award to CMA!

High Precision Wobbler SystemVertex Antennentechnik, GmbH

Aluminum Coated subreflector

Uncoated Surface

Completed Wobbler System Images of CFRP wobbler

(nutator) and Subreflector for the 12-meter APEX Telescope for Vertex Antennentechnik, GmbH & Max Plank Institute.

APEX Telescope Atacama, Chile

Radio AstronomyNutating CFRP Subreflectors

CMA’s produced 3 nutating (chopping) subreflectors for the ALMA US and Japanese Prototype 12m Telescope and 2 subreflectors for the APEX Telescope, 7.5µm rms, 12 lbs. APEX subreflector operating at 5000m altitude for 2 years yielded no change in optical performance .

750mm Diameter

APEX Image, June 2010

Radio AstronomyCosmic Background Imager (CBI) CFRP Subreflectors

CMA’s produced 13 CFRP subreflectors for the Cosmic Background Imager program (CBI). The convex hyperbolic reflectors are 150 mm diameter and weigh 80 grams each, surface accuracy of 1 µm rms. The reflectors have been in operation on the Atacam a site for 15 years.

Cosmic Background Image from CBI

CMA produced, through DR Technologies and AFRL, a gradient index of refraction, GRIN augmented solar concentration onto a single crystal PV cell. Concentrator uses K1100, high thermal conductivity carbon fibers for high efficiency of the PV cell, GRIN and PV cell shown in bottom of upper right photo.

GRIN Solar ConcentratorSpacecraft Power Generation

CMA produced the 18” X 18” precision CFRP structure to hold the 64 8X8 Orthogonal Transfer Arrays, OTA’s for the Panoramic Survey Telescope and Rapid Response System, Pan-STARRS 1, which employs the largest CCD camera in the world, 1.4 Gigapixels!,

The CFRP structure has been operational in the PS 1 telescope cryostat on the sky for nearly 3 years.

Pan-STARRS Focal Plane Array

Completed CCD Array

Photo Courtesy of J. Tonry, U of H IFA

Laser Cutting Optical Benches5 designs routinely manufactured

• 39 mm thickness• Low CTE lay-up and carbon fiber material • Commercial grade, vented aluminum honeycomb core• Aluminum and Stainless mounting inserts

Laser Cutting Optical Benches

General StructuresHexapod Extension Assembly for LSST

CMA produced a prototype extension assembly with high modulus carbon fiber materials for the LSST, under evaluation, 17.5 lbs with steel end fittings.

AMiBA Telescope Platform, 6m all-CFRP composite, weight is 2,200 lbs, left images shows platform under construction at CMA, Tucson Az.

AMiBA Telescope with 7 dishes, 60cm diameter on site on Mauna Loa October 2006

Large CFRP Structures6-meter AMiBA Telescope Platform

30cm Prototype AMiBA Dishes

Large CFRP Flight Simulator Mirror Demonstrator

Large Projection MirrorsFlight Simulator Mirrors

100-inch Spherical Mandrel, 86-inch ROC Finished coated

mirror, 1m X 1.8m

4-mirror array finished coated 2m X 3.6m

Segmented CFRP Mirrors

4-mirror Spherical Segmented array 86-inch ROC

4-mirror array finished coated 2m X 3.6m

7-mirror array unfinished CFRP blanks, 0.5m hexagonal segments

2-mirror Segmented array 86-inch ROC

6-mirror parabolic Segmented array 64-inch FL with fringes in bottom image

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Preliminary astronomical tests with 16-inch carbon fiber telescope and composite replicated optics

16-inch CFRP CompositeTelescope and Optics

13-inch LiteStar RC system

16-inch AO Cassegrain system

1m Cassegrain system

1.4m Cassegrain system

Carbon Fiber Optical Ultra-lightweight Telescopes

16-inch Cassegrain System

Ultra-lightweight 13-inch RC system 0.5m Newtonian for Photon Sieve

Design Flexibility with single mandrel set

CFRP Composite Telescopes

Off-Axis Telescope with Dual CCD’s , Weight ≈ 1kg

On-Axis Cassegrain Telescope 3.4 kg Complete with optics

0.3-m Mandrel Set for Demo OTA

Telescope Strut Tubes and CFRP End Fittings

CMA can produce all types and thicknesses of CFRP tubes.

Circular & Square cross sections

LiteStar 330330mm RC Telescope

CMA’s Prototype LiteStar, All-CFRP composite telescope with replicated composite hyperbolic f/1.2 Primary mirror. Telescope weight with optics is 5.5 lbs.

Dual FOV Off-Axis Systems Optical Assemblies

3-mirror, dual FOV off-axis system, 4” primary Weight: 1.2 lbs

Prime Focus Modef/4 system

Cassegrain Focus Mode f/40 system

ULTRA 1m all-CFRP composite optical telescope assembly (OTA) for ground-based astronomy. Telescope is shown with 27 pound 1m primary mirror. OTA weight with optics is 175 lbs. First mode frequency for the entire structure is was measured at 50 Hz., 6-axis M2 Hexapod control, Inset shows instrument package attached to the back end.

ULTRA-Lightweight 1m CFRP Telescope

Dynamic Tests of CFRP 1m Telescope

0 0.5 1 1.5 2 2.5 3 3.50

0.05

0.1

0.15

A e-α t [B sin(β t) + C cos(γ t)] + b α = 5.3061; β = 14.6149; γ = 27.9204; b = 0.056508

Time (Seconds)

Vol

ts

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 20

0.2

0.4

0.6

0.8

1

1.2

1.4

Time (Seconds)

Nor

mal

ized

sig

nal

Normalized signal with damping coefficient

∝ e-α t ; α = 5.3061 s-1

⇒ t

r = .1885 s

Example of accelerometer measurements of Example of accelerometer measurements of Example of accelerometer measurements of Example of accelerometer measurements of impulse behavior of the CFRP 1m telescope referenced against impulse behavior of the CFRP 1m telescope referenced against impulse behavior of the CFRP 1m telescope referenced against impulse behavior of the CFRP 1m telescope referenced against mount, with fitted theoretical damping constant. mount, with fitted theoretical damping constant. mount, with fitted theoretical damping constant. mount, with fitted theoretical damping constant. Result is 1Result is 1Result is 1Result is 1stststst mode frequency of ~50 Hz.mode frequency of ~50 Hz.mode frequency of ~50 Hz.mode frequency of ~50 Hz.

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CMA has produced and delivered an all-CFRP composite telescope, and Az-El mount for the Naval Research Laboratory, NRL. The telescope is an f/10 Cassegrain design with CFRP optics weighing 22 lbs total. The mount is piezo actuator driven for fast tracking capability.

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NRL 0.4m CFRP OpticalTelescope and Mount

BC: ends of yoke pins are fixed

4-noded composite elements (SHELL4L)

SOLID elements for yoke pin

BEAM3D elements for end-fitting bolts

36885 elements

36444 nodes

Total weight=260 lb

NPOI 1.4m CFRPOptical Telescope

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3-D Drawings of the NPOI System

NPOI, Naval Observatory, Anderson Mesa, Flagstaff AZ

FEA Model of the NPOI System

Navy Prototype Optical Interferometer (NPOI) 1.4m all-CFRP composite optical telescope assembly (OTA), shown in the final stages of assembly. Telescope is produced for the Naval Research Laboratory (NRL) and is the first of at least 3 identical, deployable lightweight telescopes for the interferometer in Flagstaff Arizona. Total telescope weight with optics is 250 lbs.

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NPOI 1.4m CFRPOptical Telescope and Mount

CFRP Aft Metering Structure and elliptical strut tubes for space telescope prototype for Raytheon Space and Airborne Systems, El Segundo, CA.

Telescope StructuresOptical Telescope Base and Struts

Manufacturing Prototype of CFRP microwave dish for RG-50 Active Denial system prototype for Raytheon Missile Systems, Tucson, AZ.

Microwave DishesActive Denial Systems

Front View

Back View

CFRP mirrors for concentrated photovoltaic applications. The BrightLeaf system is a hybrid producing electricity and hot water with ~60% efficiency.

CPVT Solar ConcentratorsVolume Mirror Production

Off-Axis CFRP Mirrors

3.8 kW Array 384 mirrors

Lightweight CFRP Solar Concentrator mirror and vacuum mount for Solar Thermal Propulsion project.

Space Solar ConcentratorSolar Thermal Propulsion

Low-Cost Solar parabolic concentrator Dishes

Single Mirror Dishes

Segmented Mirror Dishes

Solar Concentrator Concepts

Low-Cost Flat Formed Trough Mirror

Flexible but stiff ♦Unbreakable ♦They do not dent ♦Resistant to hail and sand ♦ Accurate surfaces ♦ Thickness tailorable ♦ Low-cost material and fabrication

Solar Collector Concepts

CFRP Composite TechnologyPrograms

Space Flight ProjectsTRL Status

Space Flight Optics MISSE-7 & 8

Optical tests of CFRP Spherical mirror samples for MISSE-7, Launch date Nov 2009, STS 129, Currently mounted in Ram direction on ISS

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3 CFRP optical mirrors in the

flight tray

Space Flight OpticsAlpha Magnetic Spectrometer, AMS-02

AMS-02 and its location on the ISS, currently on orbit operating nominally Photo courtesy of NASA JSC

Photo courtesy of CERN

*From John C. Mankins

Advanced Concepts Office

Office of Space Access and Technology

NASA, 1995

CFRP Composite MirrorsAMS-02 Rich Mirror TRL Status

AMS-02, Engineering model and final flight

model produced, TRL 8

*

AMS-02 RICH Mirror is a projection mirror operating in the blue band, 450nm.

Imaging optics will require a series of thermal stability and vacuum stability testing.

Lightweight Deformable Mirror Technology

Active/Adaptive Optics30 cm flat

(Patented Design)

Deformable CFRP MirrorsResearch and Development

1m parabola, f/3

1.5 kg/m2 ,0.91m, f/1.1Nanolaminates

16” parabola and Reaction structure

50 cm, f/2

40 cm, f/4 Segmented240 mm AO

Facesheet

50 cm piezo

CFRP Composite Mirrors EO Thermal Performance Determination

CFRP Spherical Mirrors P-V Comparisons Versus Temperature

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

50 60 70 80 90 100 110

Temperature, Deg C

Sur

face

Acc

ura

cy P

-V, M

icro

ns

Sphere 1

Sphere 2

Sphere 6

Sphere 7

Sphere 8

4-inch diameter, 13-inch ROC spherical CFRP mirrors soaked at various temperatures and measured after being brought back to RT. P-V versus Temperature

CFRP Composite Mirrors EO Thermal Performance Determination

4-inch diameter, 13-inch ROC spherical CFRP mirrors soaked at various temperatures and measured after being brought back to RT. RMS versus Temperature

0

0.01

0.02

0.03

0.04

0.05

0.06

50 60 70 80 90 100 110

rms

Sur

face

Acc

urac

y, M

icro

ns

Temperature, Deg. C

CMA CFRP Spherical Mirrors rms - vs- Temperature

Sphere 1

Sphere 2

Sphere 5

Sphere 6

Sphere 7

Sphere 8

CFRP Composite Mirrors EO Thermal Performance Determination