Additive manufacture of optical components

Abstract

A method of forming an optical component includes depositing slurry that includes glass powder material onto a facesheet and fusing the glass powder material to a facesheet to form a first core material layer on the facesheet. The method also includes successively fusing glass powder material in a plurality of additional core material layers to build a core material structure on the facesheet. The method can include selectively depositing slurry including glass powder material over only a portion of at least one of the facesheet, the first core material layer, and/or the one of the additional core material layers. Depositing the slurry can include extruding the slurry from an extruder.

What is claimed is: 
     
         1 . A method of forming an optical component comprising:
 depositing slurry including glass powder material onto a facesheet;   fusing the glass powder material to the facesheet to form a first core material layer on the facesheet; and   successively depositing and fusing glass powder material in at least one additional core material layer to build a core material structure on the facesheet.   
     
     
         2 . The method as recited in  claim 1 , wherein at least one of depositing slurry including glass powder material and successively fusing glass powder material includes:
 selectively depositing slurry including glass powder material over only a portion of at least one of the facesheet, the first core material layer, and/or the one of the additional core material layers.   
     
     
         3 . The method as recited in  claim 1 , wherein depositing the slurry includes extruding the slurry from an extruder. 
     
     
         4 . The method as recited in  claim 1 , wherein fusing glass powder material includes fusing low expansion glass powder into low expansion glass with a laser. 
     
     
         5 . The method as recited in  claim 4 , wherein fusing glass powder material includes fusing low expansion titania-silica glass powder into low expansion titania-silica glass. 
     
     
         6 . The method as recited in  claim 1 , wherein fusing glass powder material to a facesheet includes fusing glass powder material to a facesheet that is contoured for optical properties. 
     
     
         7 . The method as recited in  claim 1 , further comprising positioning the facesheet on a mandrel prior to fusing glass powder material to the facesheet. 
     
     
         8 . The method as recited in  claim 1 , wherein fusing glass powder material to the facesheet includes fusing the glass powder material to a polishable surface of the facesheet. 
     
     
         9 . The method as recited in  claim 1 , wherein successively fusing glass powder material includes forming a mirror substrate. 
     
     
         10 . The method as recited in  claim 9 , wherein forming a mirror substrate includes forming an optimal three-dimensional mirror topology that minimizes the mass of mirror substrate while providing a level of stiffness and stability above a predetermined minimum requirement. 
     
     
         11 . The method as recited in  claim 1 , wherein successively fusing glass powder material includes varying material properties in successive layers. 
     
     
         12 . An optical component comprising:
 a glass facesheet;   a first layer of low expansion glass fused to the glass facesheet; and   at least one successively fused layer forming a core material structure on an assembly that includes the facesheet and the first layer.   
     
     
         13 . The optical component as recited in  claim 12 , wherein the first layer and the at least one successively fused layer include fused low expansion glass powder material. 
     
     
         14 . The optical component as recited in  claim 13 , wherein the fused low expansion glass powder material includes fused low expansion titania-silica glass powder. 
     
     
         15 . The optical component as recited in  claim 12 , wherein the facesheet is contoured for optical properties in at least one of two-dimensions or three-dimensions. 
     
     
         16 . The optical component as recited in  claim 1 , wherein the facesheet includes a polishable surface, wherein the first layer is fused to the polishable surface of the facesheet. 
     
     
         17 . The optical component as recited in  claim 1 , wherein the facesheet, first layer, and successively fused layers form a mirror substrate. 
     
     
         18 . The optical component as recited in  claim 17 , wherein the mirror substrate includes an optimal three-dimensional mirror topology that minimizes the mass of mirror substrate while providing a level of stiffness and stability above a predetermined minimum requirement. 
     
     
         19 . The optical component as recited in  claim 12 , wherein the plurality of successively fused layers includes glass material with material properties that vary in successive layers. 
     
     
         20 . The optical component as recited in  claim 12 , wherein the plurality of successively fused layers includes glass material with material properties that vary based on position within the core material structure.