Satellite-based optical instruments must maintain extreme precision under harsh space conditions, where temperature fluctuations can induce material expansion and thus optics misalignment. Traditional metal or polymer housings struggle to achieve the required dimensional stability, often necessitating complex active thermal control systems.
We have developed an additively manufactured composite housing for the critical optical telescope subsystem for OzFuel – a space-based sensor platform that is sensitive to variations in critical fuel properties that influence the flammability of the Australian landscape. The housing is designed to provide near-zero axial thermal expansion, ensuring long-term dimensional stability for optical instrumentation.
With our robotic laser-assisted fibre placement (AFP) technology we manufactured the housing in less than 3 hours. This method enabled precise control over fibre orientation and layer build-up, ensuring uniform properties across the structure. 3D diagnostics confirmed <1% void content and precise machining for accurate lens positioning and alignment.
Key Manufacturing and Design Specifications:
- Axial coefficient of thermal expansion: <10-6, resulting in a total axial displacement of 8 microns over a 100 K temperature change
- Material: Continuous unidirectional high-strength AS4 CF/PEEK tape (55% FVF, space-qualified).
- Dimensions: outer diameter 130 mm | length 144 mm
- Laminate: thickness 12.5mm | 92 layers
- Placement Time: 180 min
Key Benefits of the Optical Mount
– Maintains perfect focus from clean room to orbit – no refocusing needed
– Built to endure – space-qualified CF/PEEK for extreme environments
– Lightweight structure – reduces launch costs or increases payload capacity
This demonstrator was developed in collaboration with the Optics and Instrumentation team at the Research School of Astronomy & Astrophysics, Australian National University for the OzFuel project, supported by the Australian Government’s Department of Industry, Science and Resources.
Find Out More
For technical details or to discuss how this solution can benefit your project, contact us at info@newfrontiertech.com.au
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