Additive Manufacturing of Biomimetic Near-Zero CTE Optical Structures

Super invar, with its near-zero coefficient of thermal expansion (CTE), has a great potential to be used in the design and fabrication of high-precision optical structures, such as optical mirror substrates. In order to reduce the weight and maintain the strength of the mirror substrate, several biomimetic lattice designs were investigated in this paper. The static modeling provides a systematic study on different types of biomimetic mirror substrates. The impact of structure parameters, such as the wall thickness, lattice unit length, height of the lattice structure, and the thickness of the side plate, are also studied. It turns out that the three-layer lattice-structured composite mirror substrate has the best performance. With AM techniques, three-layer gyroid optical structures, which are not possible to fabricate with conventional manufacturing technology, were designed and printed with our in-house-built AM machine. The stiffness test of the gyroid specimens was in good agreement with the modeling results. The gyroid structure shows about a 20% improvement over the honeycomb structure. The gyroid design reduces the equivalent density to 1.8 g/cm3 and has an order-of-magnitude improvement on the thermal deformation, while maintaining a comparable strength with that of beryllium.