CMA Profile www.compositemirrors.com Composite Mirror Applications, Inc. (CMA) was founded by Robert Romeo in 1991 to design, prototype and manufacture custom lightweight optics. CMA has developed and optimized processes for producing ultra-smooth, high precision lightweight mirrors for use in visible imaging applications and continues to advance mirror technology for UV and x-ray astronomy as well as LIDAR and partial physics applications. Mirrors manufactured by CMA are fabricated utilizing a proprietary process which is free of fiber and core print-thru and bond lines. Furthermore CMA manufactures composite mirrors from a wide range of composite materials allowing cost and design flexibility for a given application. CMA is the industry leader in ultra-smooth, extremely lightweight precision composite reflectors. 13,14 July 2005 Feasibility/Concept Study Mid Term Status Review

CMA Relevant Project Experience The CMA client list for past projects includes : Argonne National Laboratory, ASIAA, Bennett Optical Research, Brown University, CalTech, Canadian Space Agency, Carlo Gavazzi Space Center, Efficient Designs Incorporated, Harris Corporation, Harvard CFA, INFN, JPL, NASA - Goddard Space Flight Center, NRAO, NRO, National Science Foundation, Naval Research Lab, Photon Instruments Ltd., Physical Optics Corporation, QinetiQ Ltd., System Specialists Inc., University of Arizona - Steward Observatory, University of Bristol, University of Notre Dame, Vertex Antennentechnik   Previous CMA projects which are relevant to the CCAT Panel Study include Secondary Mirrors for ALMA and APEX antennas CFRP components for the ALMA and APEX chopping systems CFRP/ Aluminum sandwich tertiary mirror for the SMTO CFRP secondary mirrors for CBI dishes CFRP 16” optical wave mirrors and OTA for ULTRA and NRL projects 1m CFRP optical wave mirrors and OTA for ULTRA (in construction) 1.4m CFRP optical wave mirrors and OTA for NRL (in construction) 13,14 July 2005 Feasibility/Concept Study Mid Term Status Review

Mirror Fabrication Surface Transfer What are Composite Mirrors? Carbon Fiber Reinforced Plastic Composite material Molded over an Optical Quality Mold 13,14 July 2005 Feasibility/Concept Study Mid Term Status Review

Example of Flight Simulator Mirrors 13,14 July 2005 Feasibility/Concept Study Mid Term Status Review

Feasibility/Concept Study Mid Term Status Review Panel Design Approach CMA Personnel Involved in study: Robert Martin, Robert Romeo, and Jeff Kingsley Panel Design: Sandwich Panel construction 1.5mm CFRP face sheets of high modulus fiber lay-up Aluminum honeycomb core 3 point mounting to backside baseline panel is for 6-ring segmentation (1.83m radial side) Analysis: FEA to optimize mounting locations and panel thickness Try 7-ring segmentation and Hex panel shapes for comparison 13,14 July 2005 Feasibility/Concept Study Mid Term Status Review

Feasibility of Approach CMA panel design uses proven technology. Design is similar to SMT panels of 1.55m radial size and 5 micron rms accuracy. CMA has replicated optical wavelength surfaces of 2m (square shape). Technical feasibility is not in question. Approach is of acceptable risk. Similar products have been field tested. Manufacturing technology is successful. Manufacture has been cost effective. Challenge for CMA concept design is Value Engineering. Our design process aims to maximize performance reduce cost reduce overall weight 13,14 July 2005 Feasibility/Concept Study Mid Term Status Review

Feasibility/Concept Study Mid Term Status Review Baseline Study Panel 13,14 July 2005 Feasibility/Concept Study Mid Term Status Review

Panel Deformations under Gravity FEA evaluation done to date: Gravity Wind Size changes Shape change 0.0µ 3.8µ 13,14 July 2005 Feasibility/Concept Study Mid Term Status Review

Panel Error Budget (for all panels, worse case) general panel sub-aperture use Item rms (micron) rms (micron) Mold 1 0.05 Replication 1.5 0.10 Gravitational 2 n/a Wind (5 m/s) 1 n/a Absolute T change 1 n/a T gradient 0.5 0.2 Aging 0.5 0.3 Total (RSS) 3.1 0.38 CCAT current spec: 5 13,14 July 2005 Feasibility/Concept Study Mid Term Status Review

CMA Panel Study Program Plan 13,14 July 2005 Feasibility/Concept Study Mid Term Status Review

Feasibility/Concept Study Mid Term Status Review Remaining Study Work Study program is on schedule and there are not any problems or concerns from CMA. Continuing Work Direction: Material studies (mechanical properties) underway. Results will be used in checking current FEA. Detailed evaluation of cost factors. In particular, quantify the cost changes for panel design changes. Evaluate key capital equipment. FEA analysis for thermal loading conditions. Outline of WBS work plan for manufacture. 13,14 July 2005 Feasibility/Concept Study Mid Term Status Review