Fabrication Strategy of Additively Manufactured Metal Mirror Based on Multi-Load Topology Optimization and Single-Point Diamond Turning

This article presents a fabrication strategy on the structural design, optimization, additive manufacturing, and processing of metal mirror. Specifically, the study showcases the topology design of a metal mirror with diameter of 200 mm, the additive manufacturing of standard aluminum-based powder (AlSi10Mg), the high-precision single-point diamond turning process of the surface. By setting the feasible domain partition, a topology optimization model suitable for metal additive manufacturing and subsequent surface shaping was constructed, which takes into account the multi-load machining load conditions of single-point diamond turning technology and the material topology representation of standard support structures for additive manufacturing. The results demonstrate that the optimization model effectively suppresses the vibration phenomenon during single-point cutting. Furthermore, the results of the optical interferometer surface inspection confirm that the design and processing strategy for additively manufactured metal mirrors demonstrated in this study can be directly applied to infrared band reflective imaging optical systems.