Modern ground-based telescopes increasingly rely on larger optics, high-speed actuators, and precision instruments. These must usually be integrated into existing infrastructures resulting in competing weight budgets. The mass of traditional metal support structures is often limiting the possible upgrades, limiting performance and introducing thermal instability. For DREAMS – a new half-metre infrared survey telescope at Siding Spring Observatory – these effects would compromise focus and alignment during overnight observations.

To address this, New Frontier Technologies was engaged to design and manufacture a dimensionally stable mirror support structure that could meet the strict thermal and structural requirements of the DREAMS telescope, without adding unnecessary weight.

We developed a biaxially optimised composite structure using automated fibre placement (AFP), tailored to achieve near-zero axial thermal expansion (CTE) while matching the radial CTE of the aluminium mirror mounts.

This allowed the structure to hold its shape and maintain alignment through large temperature swings without the need for active control or compensation mechanisms.

The final structure was manufactured in under 9 hours and weighed just 8 kg – less than half of the 20 kg allocated mass budget. By using space-qualified thermoplastic carbon fibre material with low outgassing behaviour the team delivered an innovative, lightweight, and tailored CTE structure.

“NFT’s work will be significant in any type of industry sector where telescopes are needed… I think optical communications (which is growing) and space situational awareness are good examples to consider. These industries need to produce telescopes in a much larger quantities than astronomers do, and the impact of the work done by […] NFT will be felt once the expansion of optical ground stations begins across Australia. Thanks to the research and development that went into the DREAMS project, the possibilities for multiplication at the touch of a button are truly impressive. It is clear that we will soon have a volume market in Australia that will have started because of astronomy. The economy will only benefit from Australia’s leadership in this type of advanced manufacturing.” – Professor Tony Travouillon Project lead for DREAMS

Key Manufacturing and Design Specifications:

• Axial coefficient of thermal expansion: -0.56 × 10^-6 1/K
• Radial coefficient of thermal expansion: 23.5 × 10^-6 1/K (equal to that of Aluminium)
• Material: Continuous unidirectional high-strength AS4 CF/PEEK tape (55% FVF, space-qualified).
• Dimensions: internal diameter 612 mm | length 1048 mm
• Laminate: thickness 2.5mm | 18 layers
• Total mass: 8 kg
• Placement Time: < 9 hours

Key Benefits of the Optical Mount

• Maintains focus during overnight observations with temperature swings – no refocusing needed, more time to focus on your mission
• Matched interface performance – radial expansion aligned with that of the aluminium mounts while nearly no expansion in axial direction keeping the lenses aligned
• Lightweight structure – enables greater mass allocation for optical instrumentation

This demonstrator was developed in collaboration with the Optics and Instrumentation team at the Research School of Astronomy & Astrophysics, Australian National University for the DREAMS project.

Find Out More

For technical details or to discuss how this solution can benefit your project, contact us at info@newfrontiertech.com.au