Diamond Turning High Aspect Ratio Mandrels for X-ray Mirror Manufacturing

Diamond turning of high aspect ratio mandrels is a critical capability required to advance high-energy astrophysics missions, such as those conducted by NASA. A highly experienced team comprising WaveFront Technology Inc. (WFT), Moore Nanotechnology LLC (MNL), and Precision Optics Prototyping (POP) proposes to enhance the equipment, processes, and metrology developed during the 2018 manufacturing of the Imaging X-ray Polarimetry Explorer (IXPE) mirror mandrels. This enhancement aims to meet the advanced resolution and collecting area requirements for future X-ray optics. WFT operates a Horizontal Drum Lathe (HDL), which successfully produced the IXPE mirror mandrels. However, this platform needs further modifications to meet the requirements for next-generation full-shell Wolter-I X-ray optic mirror module assemblies. MNL has developed design concepts for components that can be integrated into WFT's HDL, while POP brings the necessary expertise in programming and operational integration to ensure the successful implementation of these changes, ultimately meeting NASA’s stringent X-ray optics specifications. A significant gap exists between the current capabilities of the HDL platform and the specific requirements for X-ray optics manufacturing, particularly in terms of hardware modifications and tolerance specifications for mandrel machining. This Phase 1 project will generate the necessary modeling, analysis, software, and hardware schematics to demonstrate that the proposed modifications can fulfill these critical hardware requirements. Phase 1 Objectives: 1. Specify the high aspect ratio mandrel requirements. 2. Define process requirements for the desired mandrel finish. 3. Determine diamond turning platform requirements. 4. Establish metrology requirements. 5. Prepare for system integration and feasibility assessment in Phase 2. The outcomes of Phase 1 will provide detailed specifications for the equipment required in Phase 2.

NASA’s large X-ray observatories require low-cost, ultra-stable, and lightweight mirrors, featuring high reflectance coatings and effective stray light suppression. The state-of-the-art (SOA) requirements, such as angular resolutions of 1 arcsec or better and collecting areas of 1-5 m², are currently limited by the absence of equipment capable of diamond turning high aspect ratio mandrels. The ability to perform diamond turning on such high aspect ratio mandrels will resolve this limitation, directly benefiting high-energy astrophysics missions. Precision diamond turning of cylinders is an established manufacturing technology used across industries such as aerospace, defense, electronics, semiconductors, and biomedical sectors. Applications in high-performance displays, augmented and virtual reality, lighting, and imaging would benefit from the precision advances anticipated by this project. The ability to maintain tight figure tolerances over cylinder lengths of 2m offers potential cost savings by enabling the production of larger, uniform areas, thereby advancing the state of the art across several industries.

This is a mature technology (TRL 7+) — the realistic path in is usually NASA's Technology Transfer Program: licensing an existing NASA patent, or a Space Act Agreement to use NASA facilities/expertise directly. NASA also runs a startup licensing program with no upfront fee for companies formed to commercialize a specific NASA technology.

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