Manufacturing and performance test of a 800 mm space optic

Next generation space telescopes, which are currently being developed in the US and Europe, require large-scale light-weight reflectors with high specific strength, high specific stiffness, low CTE, and high thermal conductivity. To meet budget constraints, they also require materials that produce surfaces suitable for polishing without expensive over-coatings. HB-Cesic - a European and Japanese trademark of ECM - is a Hybrid Carbon-Fiber Reinforced SiC composite developed jointly by ECM and MELCO to meet these challenges. The material's mechanical performance, such as stiffness, bending strength, and fracture toughness are significantly improved compared to the classic ECM Cesic material (type MF). Thermal expansion and thermal conductivity of HB-Cesic at cryogenic temperatures are now partly established; and excellent performance for large future space mirrors and structures are expected. This paper presents the design and manufacturing of an 800-mm mirror for space application, starting with the C/C raw material preparation to the finishing of the components, including the polishing of the mirror. The letters "HB" in HB-Cesic stand for "hybrid" to indicate that the C/C raw material is composed of a mixture of different types of chopped, short carbon-fibers.