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DIRECTED
ENERGY
PROFESSIONAL
SOCIETY
Abstract: 24-Symp-172
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UNCLASSIFIED, PUBLIC RELEASE
3D-Printed Cordierite Mirrors for HEL Applications
Large, curved mirrors used in High Energy Laser (HEL) weapon systems require low coefficient of thermal expansion (CTE) and high stiffness to maintain strict optical quality over all temperature ranges and inertial conditions. The standard low-CTE materials are heavy and the manufacturing process to light-weight, grind and polish the large glass substrates is slow. 3D-printing has potential to dramatically reduce the processing time to create a near-net curvature with pocketed grids or honeycomb cores for light-weighting. 3D-printed Silicon Carbide (SiC) has gained traction, but is difficult to grind and polish and has high CTE. Research at ARL/PSU indicates that Cordierite ceramic shows promise as an alternative material for 3D-printing HEL mirrors. The key physical properties of Cordierite, i.e. CTE and hardness, are very similar to standard low-CTE optical glasses. Exploratory investigation and testing of Cordierite powder paste formulation, extrusion, sintering, and polishing on small samples indicate processing of HEL optics is feasible.
UNCLASSIFIED, PUBLIC RELEASE
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