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In order to achieve replication of the ultra-thin metal x-ray focusing mirrors with high accuracy and efficiency, which is the key component of the EP satellite independently developed and manufactured in China, the simulation and experimental research on the demolding process of the x-ray focusing mirrors are carried out in this paper. The temperature and stress fields of the entire mandrel (aluminum) and the shell (nickel) during cooling process is simulated by finite element analysis, and the evolution of the interface stress during the demolding process is analyzed. When the temperature of the mandrel and shell decreases from 45℃ to 10℃, the equivalent stress at the interface between the mandrel and the mirror reaches 5.5MPa, which is larger than the adhesion strength between Au film and mandrel. Due to the difference in material thermal expansion coefficient between the mandrel and the mirror, it can be used to release the x-ray focusing mirror shell from the mandrel by cooling according to the experimental validation. Furthermore, the shell could separate from the mandrel by means of high precision demolding automatic device. After demolding, the angular resolution of the mirror is 25.1 "HPD (Half Power Diameter) by the x-ray testing, which meets the requirements of the project. The reliability and advancement of the technology are verified.
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