Lovell E. Comstock

FISICA: the Florida image slicer for infrared cosmology and astrophysics

We report on the design and status of the Florida Image Slicer for Infrared Cosmology and Astrophysics (FISICA) - a fully-cryogenic all-reflective image-slicing integral field unit for the FLAMINGOS near-infrared spectrograph. Designed to accept input beams near f/15, FISICA with FLAMINGOS provides R~1300 spectra over a 16x33-arcsec field-of-view on the Cassegrain f/15 focus of the KPNO 4-meter telescope, or a 6x12-arcsec field-of-view on the Nasmyth or Bent Cassegrain foci of the Gran Telescopio Canarias 10.4-meter telescope. FISICA accomplishes this using three sets of “monolithic” powered mirror arrays, each with 22 mirrored surfaces cut into a single piece of aluminum. We review the optical and opto-mechanical design and fabrication of FISICA, as well as laboratory test results for FISICA integrated with the FLAMINGOS instrument. We also discuss plans for first-light observations on the KPNO 4-meter telescope in July 2004.

Innovative Manufacturing and Test Technologies for Imaging Hyperspectral Spectrometers

Corning has developed a number of manufacturing and test techniques to meet the challenging requirements of imaging hyperspectral optical systems. These processes have been developed for applications in the short-wave visible through long-wave IR wavelengths. Optical designs for these imaging systems are typically Offner or Dyson configurations, where the critical optical components are powered gratings and slits. Precision alignment, system athermalization, and harsh environmental requirements, for these systems drive system level performance and production viability. This paper will present the results of these techniques including all aluminum gratings and slits, innovative grating profiles, snap together self-aligning mechanical designs, and visible test techniques for IR systems.

Design, fabrication, assembly, and testing of the Florida Image Slicer for Infrared Cosmology and Astrophysics (FISICA) integral field unit

We discuss the design, fabrication, assembly, and testing of the prototype Florida Image Slicer for Infrared Cosmology and Astrophysics (FISICA) Integral Field Unit (IFU). FISICA is intended for large telescopes with f/numbers close to f/15, such as the KPNO 4-m and GTC 10.4-m telescopes. It implements an image slicing approach, wherein the initial image plane is optically sliced into thin strips and the strips are optically rearranged end-to-end, whereupon the composite slit image is fed into a conventional spectrograph. We divide the field of view into 22 slices, while accommodating the entire f/15 viewing solid angle. The all-reflective instrument resides in a cryogenic dewar at the initial focal plane, and places the composite slit image output precisely at the initial focus, allowing it to interface to the existing FLAMINGOS spectrograph. The mirrors were diamond turned using various tool geometries and state-of-the-art, multi-axis tool control. The mirrors are made from a single billet of aluminum, and the optical bench and mounts are made of the same alloy as the mirrors for optimum performance during cryogenic cooling. We discuss the key design efforts, emphasizing tradeoffs among performance, volume, fabrication difficulty, and alignment requirements. We describe the fabrication, and present preliminary laboratory test results.

Real-world noise in hyperspectral imaging systems

It is well known that non-uniform illumination of a spectrometer changes the measured spectra. Laboratory calibration of hyperspectral imaging systems is careful to minimize this effect by providing repeatable, uniform illumination. In hyperspectral measurements the real world images result in non-uniform illumination. We define the resulting variation as real-world noise and we compare real-world noise to other noise sources. Both in-flight performance and calibration transfer between instruments degrade significantly because of real-world noise.

Advances in diamond-turned surfaces enable unique cost-effective optical system solutions

Corning has developed a number of manufacturing and test techniques to meet the challenging requirements of imaging hyperspectral optical systems. These processes have been developed for applications in the short-wave visible through long-wave IR wavelengths. Optical designs for these imaging systems are typically Offner or Dyson configurations, where the critical optical components are powered gratings and slits. Precision alignment, system athermalization, and harsh environmental requirements, for these systems drive system level performance and production viability. This paper will present the results of these techniques including all aluminum gratings and slits, innovative grating profiles, snap together self-aligning mechanical designs, and visible test techniques for IR systems.

Optical coherence tomography probe design for reduced artifact generation and manufacturability

Many fiber based probes used in Optical Coherence Tomography (OCT) are comprised of a spacer, GRIN lens, fiber, and a microprism. This design form suffers from many material interfaces, which induce back reflections into the sample arm of the interferometer. With so many interfaces, these probes can produce artifacts in the system’s imaging window. We present a design which has just two interfaces to minimize image artifacts. The two components of this design are the fiber endface and a reflective optic. With optimization, these two components can produce back reflections below -90dB which will minimize image artifacts. This will results in high fidelity imaging for medical diagnostics.

Optimum selection of high performance mirror substrates for diamond finishing

Due to advances in manufacturing processes, the substrate options for high performance diamond machined mirrors are expanding. Fewer compromises have to be made to achieve the needed weight, stiffness and finish while maintaining reasonable costs. In addition to the traditional mirror materials like aluminum and beryllium, there are some less common materials that can now be included in the trade space that fill the cost and performance continuum between wrought aluminum and beryllium mirrors. Aluminum and beryllium, respectively, had been the low cost/fair performance and very high cost/very high performance bounds for substrate selection. These additional substrates provide multiple near net shape blank options and processes, mostly within these bounds, that can be considered in a mirror cost versus performance trade analysis. This paper will include a summary of some advances in manufacturing processes that provide more substrate options for diamond machined mirrors with some sample performance analysis and data. This is merged with the traditional substrate options to illustrate the now larger mirror substrate trade space. Some benchmark structural analysis is provided to back up a generic mirror design trade study.

Cost-effective lightweight mirrors for aerospace and defense

The demand for high performance, lightweight mirrors was historically driven by aerospace and defense (A&D) but now we are also seeing similar requirements for commercial applications. These applications range from aerospace-like platforms such as small unmanned aircraft for agricultural, mineral and pollutant aerial mapping to an eye tracking gimbaled mirror for optometry offices. While aerospace and defense businesses can often justify the high cost of exotic, low density materials, commercial products rarely can. Also, to obtain high performance with low overall optical system weight, aspheric surfaces are often prescribed. This may drive the manufacturing process to diamond machining thus requiring the reflective side of the mirror to be a diamond machinable material. This paper summarizes the diamond machined finishing and coating of some high performance, lightweight designs using non-exotic substrates to achieve cost effective mirrors. The results indicate that these processes can meet typical aerospace and defense requirements but may also be competitive in some commercial applications.

Hyperspectral grating optimization and manufacturing considerations

Hyperspectral imaging systems are finding broader applications in both the commercial and aerospace markets. It is becoming clear that to optimize the performance of these systems, their instrument transfer function needs to be tailored for each application. Vis-SWIR systems in the full 400nm to 2500nm waveband present particular design and manufacturing challenges. A single blazed grating is inadequate for a system operating in the full vis-SWIR wavelength range. In addition, optical materials and broad band coatings present a challenge for non-reflective systems. An understanding of the application and wavelengths of interest, combined with a judicious choice of a focal plane array, can then lead to an optimized system for the specific application. The ability to tailor the grating and manufacture a wide variety of grating profiles and substrate shapes becomes a significant performance enabler. This paper will discuss how the use of optical, coating, and grating design/analysis software, combined with grating manufacturing techniques assure meeting high performance requirements for different applications.

Use of Freeform Optics to Reduce Packaging Size and Increase Performance in a Three-Mirror Anastigmat Telescope

An all-reflective telescope with challenging packaging constraints was designed both conventionally using rotationally symmetric surfaces and also with freeform optics. Significant benefits were obtained with the freeform design. Manufacturing and testing implications will also be discussed.