1. 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

2. 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

3. 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

4. Example of Flight Simulator Mirrors
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Feasibility/Concept Study Mid Term Status Review

5. 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

6. 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

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

8. 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

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

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

11. 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