Stress-relieved assembly method for a high-resolution airborne optical system

In this manuscript, we report on assembly issues of a new high-resolution airborne optical system (HRAOS), which consists of front-end optics, two after-end optical channels (electro-optical and infrared channels), and a connection module. The beam splitter (BS) plate in the connection module divides the output beam from the front-end optics by 50:50 and feeds into the after-end optical channels. The BS plate has a 116-mm elliptical shape on the major axis while the thickness is only 8 mm to meet the weight limitation of the system. As a result, a small amount of stress on the BS plate causes a relatively large deformation and ultimately leads to a serious deterioration of the image quality. To resolve this problem, we suggest a new assembly method (a four-point-bonding method) and verify it by using a finite-elements analysis. After the proposed method had been applied, the final wavefront error of the entire optical system showed a rms (root-mean-square) value of 66 nm. The error of a previous result was about 317 nm. Thermal effects were also observed.