Tolerancing, Alignment and Test of the Transiting Exoplanet Survey Satellite (TESS) Optical Assembly

The Transiting Exoplanet Survey Satellite (TESS) will carry four visible waveband seven-element refractive f/1.4 lenses, each with a 34 degree diagonal field of view. This paper describes the tolerancing, assembly and alignment methods developed during the build of the TESS Risk Reduction Unit optical system. Lens assembly tolerances were derived from a sensitivity analysis using an image quality metric customized for mission performance. The optomechanical design consists of a two-stage lens housing that provides access for active alignment of each lens using a Trioptics OptiCentric measurement system. Thermal stresses and alignment shifts are mitigated by mounting the optics with cast RTV silicone spacers into individually aligned bezels, and custom fixtures were developed to aid in RTV bonding with reduced alignment error. The lens assembly was tested interferometrically over the field of view at room temperature and results were used to successfully predict lens performance and compensator adjustments and detector shim thickness for the -75C operational temperature and pressure.