POWDER BED ADDITIVE MANUFACTURING OF LOW EXPANSION GLASS
A method of forming an optical component includes fusing glass powder material to a facesheet to form a first core material layer on the facesheet. The method also includes successively fusing glass powder material in a plurality of additional core material layers to build a core material structure on the facesheet. The method can include positioning the facesheet on a mandrel prior to fusing glass powder material to the facesheet. Fusing glass powder material to the facesheet can include fusing the glass powder material to a polishable surface of the facesheet.
1 . A method of forming an optical component comprising:
fusing glass powder material to a facesheet to form a first core material layer on the facesheet; and
successively fusing glass powder material in a plurality of additional core material layers to build a core material structure on the facesheet.
2 . The method as recited in claim 1 , wherein at least one of fusing glass powder to form the first core material layer and successively fusing glass powder material in a plurality of additional core material layers includes:
depositing powder over at least one of the facesheet, the first core material layer, and/or the one of the additional core material layers; and
selectively fusing only a portion of the powder.
3 . The method as recited in claim 1 , wherein depositing powder includes depositing powder over an entire assembly of the facesheet and any subsequently layers of glass subsequently fused thereto.
4 . The method as recited in claim 1 , wherein fusing glass powder material includes fusing low expansion glass powder into low expansion glass.
5 . The method as recited in claim 4 , wherein fusing glass powder material includes fusing low expansion titania-silica glass powder into low expansion titania-silica glass.
6 . The method as recited in claim 1 , wherein fusing glass powder material to a facesheet includes fusing glass powder material to a facesheet that is contoured for optical properties.
7 . The method as recited in claim 1 , further comprising positioning the facesheet on a mandrel prior to fusing glass powder material to the facesheet.
8 . The method as recited in claim 1 , wherein fusing glass powder material to the facesheet includes fusing the glass powder material to a side of the facesheet opposing a polishable surface of the facesheet.
9 . The method as recited in claim 1 , wherein successively fusing glass powder material includes forming a mirror substrate.
10 . The method as recited in claim 9 , wherein forming a mirror substrate includes forming an optimal three-dimensional mirror topology that minimizes the mass of mirror substrate while providing a level of stiffness and stability above a predetermined minimum requirement.
11 . The method as recited in claim 1 , wherein successively fusing glass powder material includes varying material properties in successive layers.