Additive Manufacturing Is the Key for Freeform Optics in Space

One of the increasingly important ways that additive manufacturing is being used in outer space is for the creation of better parts for satellites. Satellites are critical for our way of life, with an estimated 9039 currently orbiting earth as of December 2023 according to the website Orbiting Now. These are used for everything from weather forecasting and television to internet communications and even GPS. That’s why innovation is so important in the sector, including for the glass optics which are so critical to satellite optical payloads. And now, it seems that there is yet more news coming out of about this. Through the iLAuNCH Trailblazer program, South Australia (UniSA), VPG Innovation and SMR will work on a new optical manufacturing process, called freeform optics, using additive manufacturing.

As the name suggests, freeform optics are those that are free from constraints of symmetry in form and shape. Now, thanks to additive manufacturing, it is possible to design them by making complex shapes that can provide larger fields of view than the optics made by traditional manufacturing. This while still allowing for different sizes and enabling the parts to withstand the harshness of space. It is no surprise either that this is being done as part of the iLAuNCH Trailblazer program. It has been created specifically to help accelerate space innovation in Australia.

The team involved in the iLAuNCH freeform optics project (photo credits: iLAuNCH)

iLAuNCH Trailblazer Executive Director, Darin Lovett expanded, “This project demonstrates what iLAuNCH is all about, taking a 2021 Defence Innovation Partnership (DIP) concept demonstrator that investigated the viability of Freeform Optical Components for small satellites – and moving it into production using Australian technology for real world application.”

Using Additive Manufacturing for Freeform Optics

Though we are of course mostly interested in the use of additive manufacturing in this project, and it is true that the technologies are a core part of iLAuNCH’s competencies, what is exceptional in this case is the combination of different technologies and processes to create these incredible parts. In fact, in order to create freeform mirrors for satellites, it will be necessary to combine additive manufacturing (which kind they do not specify, but iLAuNCH has a focus specifically on DED) with traditional surface-finishing, vacuum coating and molding to create especially the mirrored surface necessary in optical applications.

Dr. Stoehr explained, “Our combined efforts will redefine the possibilities in additive manufacturing and freeform optics, promising a transformative impact on the future of space exploration. As we contribute our expertise, we are not just advancing technology but shaping a future where South Australia becomes synonymous with cutting-edge value-added manufacturing.”

Al Jawhari, the Co-Founder and Group CEO of Stärke-AMG, concluded:

 “With Australia developing new space capabilities and small satellite platforms, it is at the forefront of those developments, including the rising trend towards nanosatellite platforms. The iLAuNCH Trailblazer, in partnership with UNISQ, UniSA, Stärke-AMG, and SMR Australia, is an innovative journey pushing the boundaries of additive manufacturing to revolutionize emerging freeform optics technology. We firmly believe in the transformative power of additive manufacturing and its potential to positively reshape the manufacturing industry. We are proud to be leading those efforts that will enable innovative satellite optics design and manufacturing for Earth observation and other critical applications. Together, we are enabling a future where freeform optics will redefine the possibilities of space missions.”

You can find out about iLAuNCH HERE. What do you think of the use of additive manufacturing for freeform optics? Let us know in a comment below or on our Linkedin, Facebook, and Twitter pages! Don’t forget to sign up for our free weekly Newsletter here, the latest 3D printing news straight to your inbox! You can also find all our videos on our YouTube channel.

*Cover Photo: A satellite in space (photo credits: WikiImages from Pixabay)