Cold-shaping of thin glass foils as novel method for mirrors processing. From the basic concepts to mass production of mirrors

TL;DR

This paper introduces a cold-shaping method for manufacturing lightweight, rigid, and environmentally robust segmented glass mirrors using commercial materials, suitable for mass production in optical applications.

Contribution

It presents a novel cold-shaping process for thin glass foils, including theoretical analysis, validation tests, and industrial-scale production insights.

Findings

Finite element analysis defines structural limits.

Validated process with environmental robustness.

Cost-effective and rapid production method.

Abstract

We present a method for the production of segmented optics. It is a novel processing developed at INAF-Osservatorio Astronomico di Brera (INAF-OAB) employing commercial of-the-shelf materials. It is based on the shaping of thin glass foils by means of forced bending, this occurring at room temperature (cold-shaping). The glass is then assembled into a sandwich structure for retaining the imposed shape. The principal mechanical features of the mirrors are the very low weight, rigidity and environmental robustness. The cost and production time also turns to be very competitive. In this paper we sum up the results achieved during the r&d performed in the past years. We have investigated the theoretical limits of the structural components by means of parametric finite elements analyses; we also discuss the effects caused by the most common structural loads. Finally, the process implementation, the more significant validation tests and the mass production at the industry is described.