1. The optical upgrade of the Dark Energy Survey corrector Dr David Brooks Optical Science Laboratory Department of Physics & Astronomy University College London KICP DESpec Workshop May 30-31-2012 Design and Manufacture of the Optics

2. Introduction Optical layout Optics costs Aspheric surface ADC Future R &D 2

3. The Optical Layout Present DES DesignProposed Despec Design 3 C6 C5 ADC C5

4. New Components Original C5 to be replaced with new aspheric component. New additional C6 New 4 element atmospheric dispersion corrector. Each new component will require a support cell ADC will require a rotary drive system. Metrology system for the fibre positioner. 4

5. Glass Manufacture’s Corning, HPFS C1 grade, C5 $33,000, C6 $30,000, 12 weeks. Heraeus, Superasil 312, C5 €15,000, C6 €35,000, 22 weeks. Schott, N-BK7 £2,200, LLF1 £137,700, 1 year. Ohara, S-BSL7 €14,000, S-TIL1 & PBL1Y no bid 5

6. Material and Grinding Costs 6 Material ($)Grinding ($)Time Scale (weeks) ADC1 N-BK71,90013,0007 to 8 ADC2 LLF1100,00013,00048 to 52 ADC3 N-BK71,60013,0007 to 8 ADC4 LLF1100,00013,00048 to 52 Lens C5 HPFS33,00013,000 to 40,00012 to 14 Lens C6 HPFS30,00013,000 to 40,00012 to 14 Sub Total249,50078,000 to 132,000 Total ($)344,500 to 407,500 ADC grinding not undertaken by glass manufacturer, flat stock supplied. LLF1 specially cast due to size, new stand alone melt

7. Fine Grinding, Polishing & Coating Costs, ROM Time scale 16 to 18 months Testing, depends on accuracy required, test plate,CGH, Ofner corrector etc. Coating, Anti reflection. DES C5 cost €55,000, Coating €35,000 7 Polishing (Euro)Coating (Euro) ADC 150,000 to 60,00015,000 ADC250,000 to 60,00015,000 ADC350,000 to 60,00015,000 ADC450,000 to 60,00015,000 Lens C5180,000 to 280,00040,000 Lens C650,000 to 60,00040,000 Sub Total430,000 to 580,000140,000 Total (Euro)570,000 to 720,000

8. C5, C6 Cells & ADC Costs Material (£)Machining (£) C5 Cell20,00015,000 C6 Cell18,00012,000 ADC Cells5,00030,000 Bearings & drive system20,00010,000 Sub Total63,00067,000 Total (£)130,000 8 Other costs, Design, Technical, Transport, Etc

9. Total Estimated Cost for mechanics and optics ItemEstimated cost ($) Optical Materials344,500 to 407,500 Grinding, Polishing & Coating730,000 to 920,000 Cells and drive system210,000 Total ($)1,284,500 to 1,537,000 Metrology System for fibre placement1,000,000 9 UCL Budget($) Research & Development235,000 Total235,000

10. Listing of surface sag File : C:\Users\OSL\Documents\Despec\Despec ADC2.ZMX Title: Blanco Prime Focus Camera, Despec Design Date : WED MAY9 2012 Configuration 1of 4 Units are Millimeters. Semi-Diameter of surface 21:2.560000E+002. Algorithm assumes +z goes fromglass to air. Method: MinimumVolume Removal Best Fit SphereRadius: 9.968512E+002 Best Fit SphereVertex Offset: 2.177028E-001 Maximum Depth to Remove: 4.062672E-001 Volume To Remove: 2.269531E+004 cubic Millimeters. 5 Y-coordSagBFS SagDeviationRemove 0.00E+00 0.21770280-0.2177 5.00E+001.27E-021.25E-021.84E-040.21751895-0.21752 1.00E+015.09E-025.02E-027.37E-040.216965810-0.21697 1.50E+011.15E-011.13E-011.66E-030.216039215-0.21604 2.00E+012.04E-012.01E-012.97E-030.214732120-0.21473 2.50E+013.18E-013.14E-014.67E-030.21303525-0.21304 3.00E+014.58E-014.52E-016.77E-030.21093630-0.21094 3.50E+016.24E-016.15E-019.28E-030.208421835-0.20842 4.00E+018.15E-018.03E-011.22E-020.205477340-0.20548 4.50E+011.03E+001.02E+001.56E-020.20208745-0.20209 5.00E+011.27E+001.25E+001.95E-020.19823550-0.19824 5.50E+011.54E+001.52E+002.38E-020.193905855-0.19391 6.00E+011.84E+001.81E+002.86E-020.189085460-0.18909 6.50E+012.16E+002.12E+003.39E-020.183761665-0.18376 7.00E+012.50E+002.46E+003.98E-020.177925470-0.17793 7.50E+012.87E+002.83E+004.61E-020.171571475-0.17157 8.00E+013.27E+003.22E+005.30E-020.164699180-0.1647 8.50E+013.69E+003.63E+006.04E-020.157313685-0.15731 9.00E+014.14E+004.07E+006.83E-020.149426790-0.14943 9.50E+014.61E+004.54E+007.66E-020.141058295-0.14106 1.00E+025.11E+005.03E+008.55E-020.1322364100-0.13224 1.05E+025.64E+005.55E+009.47E-020.1229993105-0.123 1.10E+026.19E+006.09E+001.04E-010.1133958110-0.1134 1.15E+026.77E+006.66E+001.14E-010.1034863115-0.10349 1.20E+027.37E+007.25E+001.24E-010.09334376120-0.09334 1.25E+028.00E+007.87E+001.35E-010.08305468125-0.08305 1.30E+028.66E+008.51E+001.45E-010.07271962130-0.07272 1.35E+029.34E+009.18E+001.55E-010.06245404135-0.06245 1.40E+021.00E+019.88E+001.65E-010.05238887140-0.05239 1.45E+021.08E+011.06E+011.75E-010.04267099145-0.04267 1.50E+021.15E+011.14E+011.84E-010.0334636150-0.03346 1.55E+021.23E+011.21E+011.93E-010.02494638155-0.02495 1.60E+021.31E+011.29E+012.00E-010.01731558160-0.01732 1.65E+021.40E+011.38E+012.07E-010.01078387165-0.01078 1.70E+021.48E+011.46E+012.12E-010.005579991170-0.00558 1.75E+021.57E+011.55E+012.16E-010.001948228175-0.00195 1.80E+021.66E+011.64E+012.18E-010.000147606180-0.00015 1.85E+021.75E+011.73E+012.17E-010.000450852185-0.00045 1.90E+021.85E+011.83E+012.15E-010.003143076190-0.00314 1.95E+021.95E+011.93E+012.09E-010.008520149195-0.00852 2.00E+022.05E+012.03E+012.01E-010.01688677200-0.01689 2.05E+022.15E+012.13E+011.89E-010.02855418205-0.02855 2.10E+022.25E+012.24E+011.74E-010.04383752210-0.04384 2.15E+022.36E+012.35E+011.55E-010.0630528215-0.06305 2.20E+022.47E+012.46E+011.31E-010.08651345220-0.08651 2.25E+022.58E+012.57E+011.03E-010.1145264225-0.11453 2.30E+022.70E+012.69E+017.03E-020.147388230-0.14739 2.35E+022.81E+01 3.23E-020.1853785235-0.18538 2.40E+022.93E+01 -1.11E-020.2287576240-0.22876 2.45E+023.05E+013.06E+01-6.01E-020.2777579245-0.27776 2.50E+023.17E+013.19E+01-1.15E-010.3325787250-0.33258 2.55E+023.30E+013.32E+01-1.76E-010.3933789255-0.39338 2.56E+023.32E+013.34E+01-1.89E-010.4062672256-0.40627 1002.315BFSRadius of curvature at vertex982.454 Conic constant0 4th Term1.88E-10 6th Term-7.82E-15 8th Term3.78E-20 0.0010178591/vrStep size10 0conic BFS RadZ AsphereZ asp + termsROCZ SphereDiff Sp/AspDif +terms 0001004635.361002.315000 100.0508942860.0508961631004535.361002.2650.04988576-0.001008530.001010404 150.1145158520.1145253021004410.361002.2030.11224645-0.00226940.002278853 250.3181325580.3182042541004010.361002.0030.31182674-0.006305820.006377515 350.6236367930.623905241003410.361001.7040.61127173-0.012365060.012633507 451.0311237051.0318320031002610.361001.3041.01067102-0.020452680.021160979 551.540720391.5422311241001610.361000.8051.51014428-0.030576110.03208684 652.1525860892.1553714351000410.361000.2052.10984143-0.042744660.045530002 752.8669124392.871519438999010.359999.50512.80994287-0.056969570.061576566 853.6839237743.690911482997410.359998.70433.61065975-0.073264020.080251727 954.6038774784.613723619995610.359997.80284.51223431-0.091643170.101489312 1055.6270643995.640040203993610.359996.80015.5149402-0.11212420.125100007 1156.7538093086.769822453991410.359995.69596.61908295-0.134726360.1507395 1257.9844714288.002878359989010.359994.497.82500044-0.159470990.177877919 1359.319445019.338835449986410.359993.18199.13306338-0.186381630.205772067 14510.7591599810.77711809983610.359991.771310.5436759-0.215484040.233442153 15011.5184397711.53439189982135.359991.027411.2875739-0.230865840.246817961 16013.1161527513.12460103979035.359989.462212.8528435-0.263309290.271757571 17014.8198428314.81472187975735.359987.793214.5218237-0.298019170.292898212 18016.6300708516.60339939972235.359986.0216.2950412-0.335029690.308358228 19018.5474370418.48908219968535.359984.141918.1730594-0.374377630.31602278 20020.5725820920.47006162964635.359982.158520.1564796-0.416102510.313582034 21022.7061882722.54453005960535.359980.069122.2459416-0.460246670.298588444 22024.9489806324.71066117956235.359977.872924.4421252-0.506855410.268535948 23027.3017283126.96671525951735.359975.569226.7457512-0.555977120.22096406 24029.7652459429.31117248947035.359973.157429.1575825-0.607663430.153589977 25032.3403951531.74289775942135.359970.636631.6784258-0.661969380.064471973 25633.9394444433.24356125939099.359969.071433.2436098-0.6958346-4.85909E-05 C5 Aspheric Surface Edge slope = 7µ / mm 10

11. Alignment Tolerance's The alignment tolerances on Decam were tight, I know because I worked to them. Adding another asphere is possibly achievable, however the placement tolerance will have to be looked at in some detail. Numbers required for the alignment and the focal plain. 11

12. Considerations on Constructing the ADC All the new optics are thin and the optical manufactures do not like that, some have suggested a 50% thickening of all elements. The main consideration is how to support the optics during manufacture and during assembly. Having high aspect ratio components make the manufacture, that is fine grinding, polishing and testing very difficult. Not just the distortion in mounting and handling in manufacture but also ensuring that the components do not move during gluing. What AR coatings are require, any Mil specification, Mg/F2, Si/O 2, Solgel. N-BK7 optical glass has a transmission curve rising at precisely the wavelength that most UV curing cements require for cure. Bonded N-BK7 elements have lower resistance to heat, humidity, and mechanical stress than fused silica when using the same light source, length of exposure, and distance from substrates. Possible distortion problems. 12

13. Optically coupling the ADC components ADC joint, This is critical as any distortion caused by the gluing will show as a wave front error. The joints can be air gap, cemented, oiled. Each has its merits and should be investigated to establish the best possible for this application. Types of cement Dow Corning RTV type two part elastomer, Sylgard 184. Norland cements, noa 60, General purpose adhesive for bonding doublets, prisms or mounting components. noa 61 Preferred adhesive for military optics. Meets MIL-A-3920. Used for optics exposed to temperature extremes. Low shrinkage. UV curing refractive index 1.56 Lensbond cements UV curing (uv-69, uv-71, uv-74) refractive index 1.55, transparent from 0.4 to 2.5 microns. Milibond, Type UV-69 A one component, ultraviolet curing cement. Cure is achieved by using an ordinary sun lamp. Type J-91 A general purpose, one component, 100% solid ultraviolet curing optical cement. This cement meets the requirements of MIL-A-3920. Dymax optical adhesives Ultra Light-Weld ® OP-4-20632 is a clear UV/Visible light-curable fibre optical assembly adhesive designed for rapid, durable bonding of fibre optic couplings and prisms. Cargille oils, Oils and gels, They can produce any refractive index and viscosity required. 13

14. ADC Coupling Problems Adhesive failure occurs when the cement separates from the glass surface. It is seen as a shiny area in reflected light. It can be any shape and can be identified by the presence of Newton rings, or a colour fringe. Cohesive failure occurs when the cement pulls away from itself. This can be identified by the fern-like voids, called feathering, appearing along the edge of the lens or sometimes in the interior. Haze, Fog or Discoloration of Bond Layer, Generally caused by some kind of contamination, reaction to mixing vessel, humidity, or solvent. 14

15. Optically decoupling the ADC components UV Curing Cement removal Several methods can be used to remove the adhesives. Lens bond decementing agent and Milsolve to name two. The easiest and simplest method is to immerse the lens in a solvent such as methylene chloride. Usually small lenses can be separated easily before it is cured by an overnight soak. The glass can be heated in oil or other medium until the bonds break and the glass separates, this would be done at around 200°C. However these are high aspect ratio elements that will be extremely difficult to separate if there is a problem, with a high risk of total failure. RTV This can be removed with acetone, however the diameter of the ADC is large and the gap small, which will make this a long process that could effect the coating. Oil & Gel Ease of separation and cleaning. 15

16. Pros and Cons of Coupling Agent Advantages and Limitations of UV Glue There are many advantages to using UV curable optical cements. They are use in a wide variety of opto- mechanical assemblies. It allows alignment and checking of the assemblies before bonding and has a quick cure time to hold the alignment in place. It works in a wide variety of compounds to produce bonds that function in a large range of temperatures from -60 o to 180 o C. UV systems curve substrates at low temperatures. Difficult to undo. Advantages and Limitations of Elastomer Adhesive Sylgard 184 requires a primer, Dow Corning 92-023 or 1200 os, (I did not notice a primer used when bonding the ODI ADC). It allows alignment and checking of the assemblies before bonding has cured and has a very slow cure time. RTV needs to be filtered to remove particulates. Difficult to undo Advantages and Limitations of Oils and Gels They can go waxy and opaque at low temperatures. Possibility of leaks. Easy removed and replenished. Requires a reservoir of oil to compensate for temperature and topping up from time to time. Also will require lens spacers to maintain correct gap. Gel is difficult the remove air from the gap. 16

17. Oiled ADC designs Section through possible Despec ADC design 17

18. Glued ADC Designs MMT wide field corrector 18 WIYN 3.5m One Degree Imager ADC ADC on the Wide-Field Corrector for the Mayall Telescope

19. ADC Mechanics & Glass handling Rotary position sensing mechanism Geared drive system Precision bearings Lens cells Nickel iron for the C5 & C6, Stainless steel for the ADC. 19 Handling of the glass The glass for the ADC is thin and will distort under its own weight due to gravity. Thus care must be taken to ensure that the mounting sub-straight is supported correctly without any distortions. Any edge supporting ring will probably distort the glass. Fixture for holding the glass and vacuum lifting structure will be necessary to hold the glass during the gluing and curing procedure.

20. Future R & D Optimise optical design for ease of manufacture. Optics need to be thicker, by a high percentage Work with polishing companies on testing of optics. Look at other optical glasses (N-BK7, CTE to high) Investigate the best possible coupling material. Develop coupling methods. Monitor any optical distortion due to glue. Design handling equipment. Determine the optical alignment procedure. Fibre positioning metrology system. 20

21. End, Thank You Dr David Brooks Optical Science Laboratory Department of Physics & Astronomy University College London 21

22. Gravity deflection on 29mm plate Edge constrained Corner constrained 22 Extra slides

23. Bonding the ODI Atmospheric Dispersion Compensators with Sylgard 184 Gary A. Poczulp 23

24. MMT wide field corrector, ADC sub assembly Despec 24

25. Gemini ADC & image stabilizer Despec ADC glass The Keck -1 Cassegrain ADC 25 Large size slewing ring bearing