Thales SESO S.A.S S.A.S. au Capital de 449 024 € SIRET : 399 064 963 000 16 RCS : Aix en Provence 94 B 1302 APE : 2670 Z – TVA : FR 46 399 064 963
Thales SESO S.A.S. Pôle d’Activités d’Aix les Milles 305 rue Louis Armand - CS 30504 13593 Aix-en-Provence Cedex 3 France Tél : 33 (0)4 42 16 85 00 Fax : 33 (0)4 4 216 85 85 E-mail: [email protected]
Issue January 2013
INSTRUMENTAL ACTIVITIES IN SPACE
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ABOUT THALES SESO
THALES SESO is a French company created in 1965 that joined THALES Group since the 3rd of
February 2011 (78 employees with 60% of whom are engineers and technicians, ISO-9001
certified since 1998). THALES SESO is specialized in optical and mechanical design with
complete manufacturing, including AIT activities, of any kind with customized optics or fully
integrated optomechanical systems.
THALES SESO produces high accuracy optical components and systems mainly under customers’ specifications and with a special emphasis onto: - aspherical surfaces (mirrors and lenses) - lightened optics (e.g. space borne mirrors) - low roughness polishing process (less than 1 Angström RMS) - high power laser optical coatings - high accuracy and stability assembly techniques (optical contacting, glass/glass cementing, glass/metals bounding) Our capabilities for milling, grinding, lightening, polishing and coatings are for up to 2m-class optics. For more than 25 years THALES SESO has been involved in space activities, beginning with focal plan for SPOT 1 and then sunshades and mirrors, with a constant desire to develop new technologies that are space qualified (optical contacting and coatings). Recent projects can illustrate THALES SESO’s efficiency and capabilities in this field, such as all the Pleiades mirrors with their mounts, as well as a large size fully integrated Cassegrain collimator for the KOMPSAT 3 project. THALES SESO is working within different fields of activity such as Ground-based Astronomy, Space optics, X-Rays mirrors, Scientific and Governmental Research programs, General Industry,…. and delivers its products all around the world (more than 80% of THALES SESO’s revenue come from export earnings).
INTRODUCTION
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THALES SESO performs optical design and tolerance analysis (with ZEMAX-EE) as well as
mechanical design including finite elements model analysis (with PRO-ENGINEER and
NASTRAN softwares).
With our technologies we are able to model and analyze components behavior under several
environmental parameters such as temperature loads and vibrations.
We can model an entire optomechanical assembly and thus propose our services from the
conception of your custom systems to their manufacture.
DESIGN CAPABILITIES
Fish-eye lens (field of view 240°!) used to project sky and ground into a dog fight simulator
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FEM analysis of the distortion of a long X-Ray mirror vs. Temperature loads
Illustrations of THALES SESO’s design capabilities
Modelisation of a complete optomechanical assembly Concept of a telescope mount
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Milling and Lightening facilities at THALES SESO
GRINDING/MILLING OF OPTICAL
SURFACES AND MIRRORS
LIGHTENING THALES SESO is equipped with large capacity and high accuracy CFAO milling machines, used for the lightening and machining of complex large optics. Such machines can be used to generate surfaces, by milling, that can be aspherical (including direct off-axis ones) with an accuracy compatible with the next fine grinding/polishing operation. They can also be used to perform complex mirror lightening.
Machine in operation at THALES
SESO since 2007
Range: up to 2meters
Machine in operation at THALES
SESO since 1998 (+second unit
installed in 2009)
Range: 1600 x 700 mm
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Very accurate lightened (75%) on-axis parabola (Ø 800 m) for a Space Application
in its supporting tool (for tests) and view of final interferogram
Achieved surface figuring = 9 nm RMS (i.e. /70 RMS @ =633nm)
Focal length: 1,5m
Lightening of a rectangular off-axis mirrors (430mm x 115mm each)
The Final result obtained and controlled thanks to our 3D measuring machine
(accuracy is a few microns within 0.9m x 0.9m measuring range)
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THALES SESO is recognized worldwide for its outstanding technical capabilities in surface
polishing and finishing of optical components.
I / POLISHING AND FINISHING CAPABILITIES
We can manage all type of Glasses, Ceramics (Zerodur, SiC, ULE), Crystals (ZnSe, CaF2), Metals (Al, Cu, Be), semi-conductors (Si, Ge)
Depending on the need, we can polish by traditional means or using Computer Controlled Polishing Machines (CCPM) or with Magneto-Rheology Fluid (MRF) polishing
Our standard Polishing capability is presently for diameter up to 2 m (+ possibility for increase up to 2.5m)
We can also propose double side direct Polishing (for flat parallel windows)
We can propose control by interferometry
The optical shapes we can manage are flat, cylindrical, spherical and aspherical, on-axis and off-axis
We can propose very low surface micro-roughness : as low as 1 Angström RMS (measured with micro-rugosimeter MICROMAP 512)
View of one of the four 1.5m capacity Computer Controlled Polishing
Machines proprietary design of THALES SESO (in operation since the 90’s)
POLISHING
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Highly aspherical and/or large mirrors issued from CCPM
Example of a highly aspherical (and off-axis) mirror with stringent WFE requirement
(reflected single path WFE close to λ/25 RMS) polished onto the THALES SESO CCPM
A very large optical component polished at THALES SESO => φ1.4m
Spherical CV ZERODUR Mirror used as a retro-sphere in a wide
optical interferometric test set-up
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Polishing with MRF machine (capacity +/- 300mm diameter)
Double side polishing
Simultaneous polishing of a batch of optical flat/parallel windows of up to 750mm
(smaller machines for smaller window sizes are also available)
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II / SUPERPOLISHING
In the framework of X-ray mirrors for synchrotrons use, THALES SESO has developed a super-
polishing technique on different materials. We can propose surface roughness down to less
than 1 Angström RMS. This technology is very useful for example in the case of high laser
power optics. This technology is applicable with CCPM and therefore for aspherical
components.
Typical output of micro-roughness measurement (with MICROMAP 512 interferometer)
Less than 1 Angström RMS
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High quality Fabry-Perot assembly, with
additional prisms and beamsplitters + base-
plate, made out of silica. The assembly was
completely done by optical contacting (except
the 3 Invar Pads attached to the base-plate by
gluing)
I/ OPTICAL CEMENTING
THALES SESO has qualified several possibilities of suitable optical cements for gluing large
lenses withstanding large storage temperature (- 10°C to 45°C) and even with different
coefficients of Thermal Expansion.
This PLEIADES secondary mirror is fixed on its
baseplate by a monolithic ‘mushroom’ type flexure
(designed by THALES SESO), consisting of three
assemblies of dipod and blade; the glued
connection of the flexure is space qualified.
II / OPTICAL CONTACTING
When two finished flat surfaces of very good flatness are put in contact, they become a unique piece, due to the molecular attraction between the two surfaces. Tests have successfully been carried out with Silicon, Silicon Carbide, Zerodur and Fused Silica.
This technology called OPTICAL CONTACTING is qualified for Space Application (ALADIN)
ASSEMBLING
Specific product line: « DIVOLI »
SPOT(1 to 4)/HELIOS/PLEIADES
Satellite cameras
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Manufactured Components need a good optical transmission or reflection in the whole
electromagnetic spectrum (from UV to far infrared). THALES SESO has developed special
anti-reflection coatings and reflection coatings (all cleanable) to meet these constantly
increasing requirements.
THALES SESO proposes in-house coatings using different techniques (material evaporation
under vacuum as well as coating deposition by sputtering). We have two sputtering
machines: pulverization DC/DC+RF, these machines operate in clean rooms. We use special
cleaning processes to guarantee the coating stability.
We also can propose coating by sputtering for pieces up to 2000mm diameter and 250mm
thickness thanks to a tank at THALES SESO’s disposal at the Cote d’Azur Observatory.
Coating by sputtering for pieces up to 1500mm by 200 mm, thickness 150mm
OPTICAL COATINGS
View of the internal part of the
φ1.1m vacuum chamber
(which has been upgraded for a
1.8m capacity)
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Some examples of typical space qualified coatings are described here-after:
SPACE QUALIFIED ANTI-REFLECTION COATING
THALES SESO has a long experience with antireflective coatings. Coatings have been developed for harsh environment programs such as:
AR coating dedicated to space applications, with the following characteristics:
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DURABLE SILVER COATING
THALES SESO has developed for space applications a protected silver coating that is very
durable and cleanable. Such coating can also be proposed for mirrors for Astronomy, which
requires simultaneously severe environmental conditions and long life duration. This coating
corresponds to the qualification certificate provided here after.
References for this space qualified coating:
PLEIADES (2005-2006)
SENTINEL 3 (2009)
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HARD GOLD COATING
THALES SESO has developed for different space programs (Envisat/MIPAS ESA experiment as
well as for the MIRI experiment of the James Webb Space Telescope) but also for several
ground-based applications, an hard gold coating allowing good reflectivity up to λ=25
microns (we have tested it up to 100 microns for space thermal applications) and a good
behavior in severe environments (MIL norms C48497-A for adherence, abrasion, humidity,
thermal cycling, cleanability ...). This coating is also fully compatible with cryogenic
applications. The typical curve is provided hereafter.
References for this space qualified coating:
MIPAS (1994)
IASI (2000)
MIRI (2006)
Hard Gold coating results (from 0.7 µm to 25 µm)
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PLEIADES MIRRORS
THALES SESO has developed the PLEIADES assembled mirrors. This development is part of the future French Earth observation system and has been ordered by the French Space Agency CNES, jointly to ASTRIUM for the bus and to ALCATEL Space for the payload.
Off-axis Aspherical 430x115 mm, 80 % lightened
THALES SESO was in charge of design and manufacture of the assembled mirrors (4 mirrors
and Mechanical Fixation Devices (MFD)). The requirements were expressed in terms of instrument performances which means that optical performances (aperture, WFE, reflectivity), mechanical performances (mass, stiffness, mechanical environment to be withstood) and other environmental parameters were taken into account in the architecture and design (thermal, radiation,..). Interfaces were considered at the base of the assembled mirror fixations. Pleiades mirrors have been assembled and tested on tooling baseplates. FM1 and FM2 deliveries were done in 2006. This program gave THALES SESO a great degree of maturity in engineering, production, assembly and testing of high precision mirrors for space instruments.
The pictures below illustrate the concepts developed within the frame of PLEIADES. All these mirrors are made of Zerodur class 0, protected silver coated and mounted on Invar flexures. A few other mirrors also manufactured by THALES SESO are part of the camera.
EXAMPLES OF DELIVERED
COMPONENTS/SUB-SYSTEMS
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M3 Mirror PLEIADES integrated M3
PLEIADES primary mirror 660mm
elliptic concave
Secondary mirror 160 mm diameter
hyperbolic
PLEIADES MR
Central mirror from the PLEIADES focal plan
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T2L2 TIME CONTROL
The Purpose of the experiment was to know the correspondence between ground based
clocks and embarked clocks within about a few pico seconds. One of the stakes, among
others, is the validation (or the invalidation) of the relativity stated by Einstein and which has
difficulty being connected to the other elements of physics…
The program started in summer 2005 with the aim of having the system installed on satellite
at summer 2007. Taking into account the kick off and test phases at CNES, THALES SESO had
only one year to carry out a flight model, including tests and qualification. THALES SESO
achieved its goal as materials were delivered in December 2006 with a contract signed in
December 2005.
THALES SESO provided 3 subassemblies in the project.
The lenses subassembly: located outside the satellite, it includes two “objectives” (linear
and nonlinear) which receive the signal coming from a ground based laser to transmit it
in optical form and electronic form to the detection rack located in the satellite.
Optical cases :
- Incident angle : 0-55° - linear optical case: the illumination profile is corrected within a range 20 (ratio
between the minimum and the maximum of the signal) – 10 nm width interferential filter – integrated detector for signal synchronization – electrical harness connection
- nonlinear optical case: the illumination profile is corrected within a range (ratio between the minimum and the maximum of the signal) – optical harness connection
Linear optical case Nonlinear optical case
Photo detector
Fiber optic connector
Spatial filter
lenses
lenses
electronics Spatial & spectral filter
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The detection subassembly: located in the satellite, following an optical delay line, an
objective receives the visible signal and focuses it on a detector of great sensitivity, after
having carried out a spectral filtering of 2 nm width!
Detection subassembly:
- Optical delay line (fiber): it enables to wait for the signal coming from the linear objective and to synchronize the non linear detector.
- Optical module : the nonlinear detector is placed at better than 30µm from the focal point in the three axes
The harness subassembly: fiber optic link between the external cases and the detector
rack.
Optical harness :
Index gradient fiber with a 100µm diameter and a N.A. of 0.29 selected for its radiation
withstanding capacity
Lenses subassembly during the tests in vibration
Delay line and coupling objective during integration
Withdrawal of last protections before launching
Some figures:
A total duration of 1 year for the study, the manufacture and the tests of the flight equipment.
A precision in the time measurement within a few pico seconds.
A working altitude of 1336 km
A 532 nm working wavelength
A compensation of the uniformity of illumination within a few % in the +/- 55°field.
A control of the spectral precision better than 0.3 nm in the temperature range of -20°C/+ 50°C.
A withstanding radiation level of 30 Mrad over a 3 year lifetime.
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KOMPSAT 3 MIRRORS
THALES SESO has designed, manufactured, tested (vibrations, thermal vacuum) and delivered the flight model mirrors of KOMPSAT 3 instrument (KARI). The five Mirrors are defined as follows:
- M1 mirror with an external diameter bigger than 800 mm, M1 mirror is lightened with a central hole with a 255mm diameter. The optical face is concave aspherical and on axis.
- M2 mirror with an external diameter
bigger than 200 mm, M2 mirror is lightened with an optical face convex aspherical and on axis.
- M3 mirror is a rectangular concave off-axis lightened mirror of 324 mm x 234 mm dimensions
- M4 mirror is a concave aspherical on axis mirror with a flat cut
- M5 mirror is a rectangular flat mirror of 161 mm x 111 mm dimensions
M1, M2 M3 and M4 mirrors are coated with a protected silver coating. M5 mirror is coated with a dielectric coating.
For this space program THALES SESO has realised a large Cassegrain Collimator for optical
testing purpose (1m-class with lightened optics, Carbon Fibre mechanical Structure, all
vacuum compatible) including also the delivery of a 1m-class autocollimation reference flat
mirror and the isolated supporting Optical Bench.
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Motorized flat mirror
Fully integrated Cassegrain collimator
Collimator+Flat mirror installed
onto the supporting bench
Collimator+Flat+Bench installed
inside the vacuum chamber
THALES SESO’ s work :
- Complete optomechanical design (including FEM)
- Complete optical and mechanical manufacturing
- Assembly and tests in THALES SESO’s facilities
- On-site installation + acceptance + training
- Vacuum compatible optical bench and dampers
Cassegrain Collimator performances :
- EFL#30m – Structure length 3200mm
- Useful aperture Ø1000mm
- Mass: total 540kg (structure 320 kg)
- Stability 2µm over 15°C-25°C
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IASI HOP TELESCOPE (off-axis parabolic mirrors)
For this program, we designed, developed, manufactured and tested in environment the off-axis parabolic mirrors for spectrometer IASI HOP (ALCATEL). Three flight model sets of two mirrors (each mirror has a diameter of 104mm and 131mm off- axis) were delivered (the last one in 2000). The mounting interface was off- axis.
ETGAR PROJECT - MIRRORS
The three ETGAR Project (ELOP – Israel) mirrors are used for a Korch type telescope. THALES
SESO has manufactured the mirrors on the basis of customer’s specification. THALES SESO
was in charge of lightening, polishing and coating for two flight model sets of three mirrors.
M1 mirror (diameter 700 mm) is a centered aspherical mirror lightened by hexagonal cells
M2 mirror is hyperbolic and has a 164 mm diameter
M3 mirror is an elliptic off-axis mirror
These mirrors have been manufactured with roughness better than 5Å on their whole
surface.
Cavity made of 2 off-axis mirrors under vibration tests
Parabolic off-axis mirrors, 108 mm diameter, off-axis 131 mm
The control of polishing processes,
even on off-axis parts, ensures obtaining a
roughness of 5Å on ETGAR M3 mirror
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SPIRALE – MIRRORS SPARES
For this project, THALES SESO has developed the M1 and M2 spare flight model. Both are Zerodur off-axis mirrors integrated on mounts. THALES SESO was in charge of the design, manufacture and test (including vibrations). M1 mirror has a 183 µm (F/0.86) departure (difference versus best fit sphere) and a 160 mm diameter.
Mirror with tilted optical face
compared to the interface plane.
M2 mirror is also an off-axis parabola with 23 mm diameter (F/0.79).
OPTICAL TELECOMMUNICATION
RUAG SPACE AG (formerly known as OERLIKON SPACE AG) is building a high performance space telescope for optical telecommunication with mirrors from THALES SESO. For this project, THALES SESO is in charge of manufacturing all off-axis mirrors which constitute the TMA system.
M1 is an off-axis mirror with a 150 mm diameter, a 286 µm departure and a 12.5 nm rms surface quality.
M2 mirror is off-axis with a 21 mm (F/0.78) diameter.
DIVOLI - SPOT 1 to 4 SATELLITE CAMERA
- Reconstitution of a line of 6000 pixels with 4 CCD
- Distance smaller than 2 µm with respect to a perfect line
- Better resolution on request
Detector linear array
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RADIOMETRE METEOSAT
Manufacture of passive cooler components for passive cooling baffling of the Detector Head of the METEOSAT Camera
Cooling to 80 K 5%
SARAL – Corner Cubes
For this project THALES SESO was in charge of the realisation of a retroreflector boarded on the satellite SARAL. LRA (Laser Retroreflector Array) is a passive instrument composed of 9 mirrors reflecting laser beams coming from ground stations located onto the earth globe. The corner cubes are placed into a mechanical housing offering a conical shape. This arrangement is used to reflect the laser beams within an azimuth angle of 360° and 150° on the perpendicular axis. Because of the launch and flight conditions the assembly method had to be robust, stable and precise, as well as compatible with space vacuum and radiations.
The 9 Corner Cubes
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LRA CAD view LRA analyses models
LRA deviation (left) and PSF (right)
Some figures: Mechanical characteristics Mass: 1.2 kg Dimensions: Øe163 mm / H66 mm Possible customization
Performances
Deviation: 7.2 arcsec ± 2.4 arcsec
Dihedral angle: 1.6 arcsec ± 0.5 arcsec
Clear aperture: Ø 32 mm
Coating: Enhanced silver
Specific MLI (Multi Layer Insulation)
Grounded
Thermistor equipped
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SOLAR SIMULATORS
Large area, UV, IR, Collimated, Double output and high spectral quality Solar Simulators
Customers: ESA, INTA, CNES, AEROSPATIALE, etc …
SOLAR SIMULATORS are designed to reproduce in a laboratory or space
simulation chambers, the conditions outside the Earth’s atmosphere to which
satellites are subjected during orbit. They also can be used in laboratories to
reproduce on Earth solar illumination conditions.
Applications:
- Study of thermal effect of solar radiation on the satellite or its
components
- Testing operation of the various elements using solar radiation as a
source of energy (solar cells) or as means of guidance (accurate sensors)
This simulation technology, completely mastered by THALES SESO, may easily be
adapted to meet the specific needs of a customer.
The optical system has been adapted to provide a uniform collimated beam for
testing solar sighting devices needed to simulate the surface diameter of the sun.
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MAIN REFERENCES (IN SPACE)
TELESCOPES, MIRRORS AND LENSES:
- ETGAR Mirrors ELOP - KOMPSAT3 Mirrors - Optical Telecommunication Mirrors
KARI OERLIKON-CONTRAVES
- SPIRALE spare Mirrors THALES ALENIA SPACE - PLEIADES HR - VENUS
ALCATEL ELOP
- IASI HOP Telescope (off-axis parabolic mirrors) ALCATEL - EVRIS Lenses LAS - MIPAS-ENVISAT Telescope - Mock up of Silex Telescope
OERLIKON-CONTRAVES ASTRIUM
- Phobos Telescope LPSP - Giotto and Vega Telescope ESA
CORNER CUBES:
- SARAL Corner Cubes
- HALLOW Corner Cubes
FOCAL PLANE – OTHER COMPONENTS:
CNES
CNES
- GAIA Prisms GALILEO AVIONICA - Spectrometer ALADIN ESA/ASTRIUM/OERLIKON-CONTRAVES - Focal plane mirrors PLEIADES HR SODERN - Focal plane array of HELIOS 1&2 DGA/SODERN - Focal plane array of SPOT 1 to SPOT4 CNES/SODERN
SUNSHADE / BAFFLES:
- IASI Sunshade ALCATEL - ISO Sunshade ALCATEL - Meteosat Cryostat
BERTIN
OGSE:
- Collimator – Flat mirror Ø1m KARI
- Solar Simulator INTA/SPACEBEL/ESA/ISRO/... - OGSE Collimator - OGSE Collimator - Vacuum compatible optical bench
DGA/ALCATEL CSL ESTEC
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THALES THALES SESO’s PUBLICATIONS IN SPACE RELATED ACTIVITIES
SOLAR SIMULATOR:
Year Date Place Conference Subject Author 1997 24th-27
th of June
(SP-408 August 97) Noordwjik, The Nederlands
Proc. of the Third Int. Symp. On Environmental Testing for Space Programmes
SOLAR SIMULATOR Michel DETAILLE Alain AUCLAIR
2001 11th-14th
of June Marseille, France Proceedings-ETTC Conference SOLAR SIMULATOR Michel DETAILLE 2008
14
th-19
th of Sep.
Konstanz, Germany
ESCP 08 (8
th European Space
Power Conference)
SOLAR SIMULATOR
A.GRAS
J.M. FERNANDEZ-MARIN J.M. AGUILAR
P. Robert C. Baur
COATING:
Year Date Place Conference Subject Author 2003
29
th of Sep.-3
rd of
October
St.Etienne, France
Optical Systems Design, 2003
R and AR coatings for high power laser and for X, DUV, VIS, IR wavelengths
Serge DUMARTIN Patrick ROBERT Laurent HAYER
2006
27th-30
th of June
Noordwjik, The Nederlands
6
th Conference on Space Optics
ESTEC
Engineering tool for the qualification of optical coatings
Marilyne DAVI Daniel PERRIN
Michel LEQUIME Dominic DOYLE
LIGHTWEIGHTING (Mirrors and Baseplate):
Year Date Place Conference Subject Author 2008
23th-28
th of June
Marseille, France
Astronomical Telescope and Instrumentation
Light and Lightweighted mirrors for Astronomy
Denis FAPPANI
2008
14th-17
th of Sept.
Toulouse, France
ICSO 2008
Innovative lightweight baseplate solution for stable optical benches in Space programs
Elisabetta Rugi Grond
Andreas Herren Stève Mérillat
Jean-Jaques FERME 2010
29th of June-2
nd of
July
San Diego, USA
SPIE Astronomical Instrumentation
Recent Achievements with a Cryogenic Ultra-Lightweighted HB-Cesic Mirror
Matthias R. KRODEL
Peter HOFBAUER Christophe DEVILLIERS
Zoran SODNIK Patrick ROBERT
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MANUFACTURING AND POLISHING OF ASPHERICAL MIRRORS:
Year Date Place Conference Subject Author 2004
21st-25
th of June
Glasgow, UK
SPIE 5494-14 Astronomical Telescopes and Instrumentation
Criterion to appreciate difficulties of spherical polishing
Christian du JEU
2004
12th-13
th of Oct.
Rochester, USA
Conference OPTIFAB 88
th OSA
2004 – 04 – C -1091 - OFT
Criterion on aspherical manufacturing used as guideline for design
Christian du JEU
2008
14
th-17
th of Oct
Toulouse, France
ICSO 2008
Manufacturing&Control of the aspherical mirrors for the telescope of the French satellite Pleides
Hélène DUCOLLET Christian du JEU
Jean-Jacques FERME
OPTICAL CONTACTING:
Year Date Place Conference Subject Author 2003 2010
29st of Sept.-3rd of October 4
th – 08
th of Oct
St. Etienne, France Island of Rhodes, Greece
Optical systems Design 2003 ICSO 2010
Optical Contacting Manufacturing&Test of the spaceborne camera mirrors for Kari’s Satellite
Jean-Jacques FERME
Hélène DUCOLLET Christian du JEU
Dr SEUNG-HOON LEE
CORNER CUBES:
Year Date Place Conference Subject Author 2008
14
th-17
th of Oct.
Toulouse, France
ICSO 2008
High Stability Hollow Corner Cube
Jean-Jacques FERME
2010
4
th -05
th of Oct.
Island of Rhodes, Greece
ICSO 2010 - International Conference on Space Optics
Development of the Laser Retroreflector Array (LRA) for SARAL
Vincent Costes
Karine Gasc Pierre Sengenes Corinne Salcedo
Stephan Imperiali Christian du Jeu
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DIPLOMA
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