The Use of Composite 3D Printing in the Design of Optomechanical Components

This article demonstrates that 3D-printed parts can replace metal parts in optomechanics in the correct circumstances. Three examples are shown: a clamping fork for pedestal holders where stability is important, an adjustable mirror holder where the rigidity is the main criterion, and a stray light shield where the transmissivity is critical. By combining carbon-fiber-reinforced polymers (CFRPs) with 3D printing, it is possible to produce components that fill the gap between standard 3D-printed plastics and metal parts in terms of strength and stability. These parts are designed to be lighter, more compact, and easier to modify, while keeping good mechanical properties such as resistance to vibration, shape accuracy, and controlled thermal expansion. The article focuses on the application of composite 3D printing on optomechanical components. It compares different methods of composite 3D printing, including fused filament fabrication (FFF) with either chopped fibers or with continuous fiber reinforcement. Three examples from the HiLASE Centre demonstrate how these parts are used in practice, confirming that it is indeed possible to 3D print components that are lighter and cheaper yet still highly functional compared to their off-the-shelf counterparts—for example, lightweight and stiff mounts, shielding against stray laser light, or flexible elements allowing fine mechanical adjustments. Simulations of the deformations are included to compare the printed and metal versions. The article ends with a summary of the benefits and limitations of using 3D-printed composites in optomechanics.