18 August 2005 Composite mirror replication: curing, coating and polishing
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The quickest method for generating a lightweight composite optic is to replicate an optical quality glass tool onto a carbon fiber reinforced polymer (CFRP). However, the effects of fiber print-through create an unacceptable surface roughness on replicated CFRP mirrors. In order to mitigate fiber print-through, two methods of generating a polishable resin layer were investigated. The first method employs the application of resin films to the CFRP surface. The second, unconventional method generates a co-cured resin layer using a magnetic fiber migration approach. A final polishing step was used to attain optical quality surface features on all of the replicated specimens. Replicated resin films with thicknesses ≥ 0.25 mm sufficiently mitigate fiber print-through. Room temperature and high temperature cure resins were polished below 50 Å rms surface roughness (1 μm to 1mm bandwidth) or better. The magnetic fiber migration technique was suitable for eliminating fiber print-through. Replicated magnetic fiber laminates were polished to within specular quality as well.
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Jack J. Massarello, Jake D. Hochhalter, Paul A. Fuierer, Arup K. Maji, "Composite mirror replication: curing, coating and polishing", Proc. SPIE 5868, Optical Materials and Structures Technologies II, 58680O (18 August 2005); doi: 10.1117/12.614603; https://doi.org/10.1117/12.614603

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