The structures that surround and support optical components play a key role in the performance of the overall optical system. For aerospace applications, creating an opto-mechanical structure that is athermal, lightweight, robust, and can be quickly developed from concept through to hardware is challenging. This project demonstrates a design and fabrication method for optical structures using origami-style folded, photo-etched sheetmetal pieces that are micro-welded to each other or to 3d printed metal components. Thin flexures, critical for athermal mounting of optics, can be thinner with sheetmetal than from standard machining, which leads to more compact designs and the ability to mount smaller optics. Building a structure by starting with the thinnest features, then folding that thin material to make the ''thicker'' sections is the opposite of standard machining (cutting thin features from thicker blocks). A design method is shown with mass savings of >90%, and stiffness to weight ratio improvements of 5x to 10x compared to standard methods for space systems hardware. Designs and processes for small, flexured, actively aligned systems are demonstrated as are methods for producing lightweight, structural, Miura-core sandwich panels in both flat and curved configurations. Concepts for deployable panels and component hinges are explored, as is a lens subcell with tunable piston movement with temperature change and an ultralight sunshade.
Developers of optical systems are seeking lighter, cheaper, and rapidly-developed systems. Design, fabrication, and testing a 10x dual-focus telescope is presented utilizing additive manufacturing, active alignment, and image correction algorithms.
Sandia National Laboratories will provide technical assistance, within time and budget, to Requester on testing and analyzing a microneedle-based electrolyte sensing platform. Hollow microneedles will be fabricated at Sandia and integrated with a fluidic chip using plastic laminate prototyping technology available at Sandia. In connection with commercial ion selective electrodes the sensing platform will be tested for detection of electrolytes (sodium and/or potassium) within physiological relevant concent ration ranges.