S. M. Miller

Deformable secondary mirrors for the LBT adaptive optics system

We describe the manufacture of thin shells for the deformable secondary mirrors of the LBT adaptive optics system. The secondary mirrors are thin shells, 910 mm in diameter and 1.6 mm thick. Each mirror will have its shape controlled by 672 voice-coil actuators. The main requirement for manufacture of the shell is smoothness on scales too small to be adjusted by the actuators. An additional requirement is that the rear surface match the reference body within 30 μm peak-to-valley. A technique was developed for producing smooth surfaces on the very aspheric surfaces of the shells. We figure the optical surfaces on a thick disk of Zerodur, then turn the disk over and thin it to 1.6 mm from the rear surface. Figuring is done primarily with a 30 cm diameter stressed lap, which bends actively to match the local curvature of the aspheric surface. For the thinning operation, the mirror is blocked with pitch, optical surface down, onto a granite disk with a matching convex surface. Because the shell may bend during the blocking operation and as its thickness is reduced to 1.6 mm, figuring of the rear surface is guided by precise thickness measurements over the surface of the shell. This method guarantees that both surfaces of the finished shell will satisfy their requirements when corrected with small actuator forces. Following the thinning operation, we edge the shell to its final dimensions, remove it from the blocking body, and coat the rear surface with aluminum to provide a set of conductive plates for capacitive sensors.

The adaptive secondary mirror for the Large Binocular Telescope: results of acceptance laboratory test

The first of the two Gregorian Adaptive Secondary Mirror (ASM) units for the Large Binocular Telescope (LBT) has been fully integrated and tested for laboratory acceptance. The LBT unit represents the most advanced ASM device existing in hardware. The unit has 672 electro-magnetic force actuators to change the shape of the 1.6mm-thick and 911mm-diameter Zerodur shell. The actuators control the mirror figure using the position feedback from the internal metrology provided by co-located capacitive sensors. The on-board real-time control electronics has a parallel computational power of 163Gflop/s providing not only the internal control of the unit with a 72kHz loop but also the wavefront reconstruction for the 1kHz Adaptive Optics loop. The paper describes the final configuration of the system and reports the results of the characterization and optimization process together with the results of the laboratory acceptance tests.

Manufacture of a 1.7m prototype of the GMT primary mirror segments

We have nearly completed the manufacture of a 1.7 m off-axis mirror as part of the technology development for the Giant Magellan Telescope. The mirror is an off-axis section of a 5.3 m f/0.73 parent paraboloid, making it roughly a 1:5 model of the outer 8.4 m GMT segment. The 1.7 m mirror will be the primary mirror of the New Solar Telescope at Big Bear Solar Observatory. It has a 2.7 mm peak-to-valley departure from the best-fit sphere, presenting a serious challenge in terms of both polishing and measurement. The mirror was polished with a stressed lap, which bends actively to match the local curvature at each point on the mirror surface, and works for asymmetric mirrors as well as symmetric aspheres. It was measured using a hybrid reflective-diffractive null corrector to compensate for the mirrors asphericity. Both techniques will be applied in scaled-up versions to the GMT segments.

The adaptive secondary mirrors for the Large Binocular Telescope: a progress report

The two 911mm-diameter adaptive secondary (AS) mirrors for the Large Binocular telescope (LBT) are currently under manufacturing process. Each unit has 672 electro-magnetic force actuators. They control the figure of the Gregorian secondary 1.6mm-thick mirrors with an internal loop using the signal of co-located capacitive sensors. The obtained computational power of the on-board control electronics allows to use it as real-time computer for wavefront reconstruction. We present the progress in manufacturing and assembling of the first telescope unit, the progress in software production, the status of the testing facilities and an update on the latest modification of the design.

Manufacture of a combined primary and tertiary mirror for the Large Synoptic Survey Telescope

The Large Synoptic Survey Telescope uses a unique optomechanical design that places the primary and tertiary mirrors on a single glass substrate. The honeycomb sandwich mirror blank was formed in March 2008 by spin-casting. The surface is currently a paraboloid with a 9.9 m focal length matching the primary. The deeper curve of the tertiary mirror will be produced when the surfaces are generated. Both mirrors will be lapped and polished using stressed laps and other tools on an 8.4 m polishing machine. The highly aspheric primary mirror will be measured through a refractive null lens, and a computer-generated hologram will be used to validate the null lens. The tertiary mirror will be measured through a diffractive null corrector, also validated with a separate hologram. The holograms for the two tests provide alignment references that will be used to make the axes of the two surfaces coincide.

Manufacture of the second 8.4 m primary mirror for the Large Binocular Telescope

The second 8.4 m primary mirror and its active support system were delivered to the Large Binocular Telescope in September 2005. The mirror was figured to an accuracy of 15 nm rms surface after subtraction of low-order aberrations that will be controlled by the active support. The mirror was installed into its operational support cell in the lab, and support forces were optimized to produce a figure accurate to 20 nm rms surface with no synthetic correction. The mirror was polished on a new 8.4 m polishing machine that gives the Mirror Lab the capacity to process up to four 8.4 m mirrors simultaneously, with each mirror going through a sequence of stations: casting furnace, generating machine, polishing machine, and integration with its support cell. The new polishing machine has two carriages for polishing tools, allowing use of two 1.2 m stressed laps during loose-abrasive grinding and early polishing, followed by final figuring with a stressed lap and a small tool for local figuring.

Adaptive secondary mirrors for the large binocular telescope

The two 911mm-diameter adaptive secondary (AS) mirrors for the Large Binocular telescope (LBT) are currently under construction. The design of the units has been based on the extensive experience made on the MMT adaptive secondary mirror during laboratory tests and telescope runs. Mechanics, electronics and control logic have been revised to improve performances and reliability. Each unit has 672 electro-magnetic force actuators. They control the figure of the Gregorian secondary 1.6mm-thick mirrors with an internal loop using the signal of co-located capacitive sensors. The improvement in the computational power of the on-board control electronics allows to use it as real-time computer for wavefront reconstruction. We present the progress of the final unit construction and the preliminary laboratory results obtained with a 45-actuator sub-system used to test the new features introduced in the electronics and mechanics of LBT adaptive secondary mirrors.

Manufacturing meter-scale aspheric optics

Deterministic subaperture finishing technologies, such as Magnetorheological Finishing (MRF(R)) are becoming the industry standard for finishing high precision optics with complex shapes, such as aspheres. However, astronomical or very large optics were beyond the scale of existing capabilities and relied on traditional, artisan-based methods of manufacture. It is not uncommon for these critical parts to spend a year or more in production. Recent developments from QED Technologies(R) have expanded MRF technology to enable the manufacture of meter-scale aspheric optics. QED, in conjunction with the Steward Observatory Mirror Laboratory (SOML) at the University of Arizona, demonstrated the fabrication of an 840 mm diameter convex asphere with 1.3 mm of aspheric departure from a best-fit sphere. Long-trace profilometry scans were initially performed at SOML to characterize the surface. A first figure correction polishing iteration was conducted at QED Technologies in Rochester, NY on a meter-class MRF machine (Q22-950F). The correction improved the surface to within the capture range of a full aperture interferometric test performed at the Mirror Lab. A final polishing iteration at QED improved the surface to meet the optic specifications.

Design and manufacture of 8.4 m primary mirror segments and supports for the GMT

The design, manufacture and support of the primary mirror segments for the GMT build on the successful primary mirror systems of the MMT, Magellan and Large Binocular telescopes. The mirror segment and its support system are based on a proven design, and the experience gained in the existing telescopes has led to significant refinements that will provide even better performance in the GMT. The first 8.4 m segment has been cast at the Steward Observatory Mirror Lab, and optical processing is underway. Measurement of the off-axis surface is the greatest challenge in the manufacture of the segments. A set of tests that meets the requirements has been defined and the concepts have been developed in some detail. The most critical parts of the tests have been demonstrated in the measurement of a 1.7 m off-axis prototype. The principal optical test is a full-aperture, high-resolution null test in which a hybrid reflective-diffractive null corrector compensates for the 14 mm aspheric departure of the off-axis segment. The mirror support uses the same synthetic floatation principle as the MMT, Magellan, and LBT mirrors. Refinements for GMT include 3-axis actuators to accommodate the varying orientations of segments in the telescope.

Progress in manufacturing the first 8.4 m off-axis segment for the Giant Magellan Telescope

The first of the 8.4 m off-axis segments for the primary mirror of the Giant Magellan Telescope is being manufactured at the Steward Observatory Mirror Lab. In addition to the manufacture of the segment, this project includes the development of a complete facility to make and measure all seven segments. We have installed a new 28 m test tower and designed a set of measurements to guide the fabrication and qualify the finished segments. The first test, a laser-tracker measurement of the ground surface, is operational. The principal optical test is a full-aperture interferometric test with a null corrector that includes a 3.75 m spherical mirror, a smaller sphere, and a computer-generated hologram. We have also designed a scanning pentaprism test to validate the measurement of low-order aberrations. The first segment has been cast and generated, and is in the process of loose-abrasive grinding.