Replicated Mirrors Capabilities - Overview

Since 1977, Newport Corporation has been providing superior Corion® brand replicated optical components which provide maximized ease-of-use at minimum cost while surpassing functional performance expectations. Whether it's a simple, spherical, front-surface mirror in quantities of thousands per year or a very large aspheric mirror on a composite substrate, our team of optical and mechanical engineers, manufacturing technicians, and metrology specialists ensure that the finished products will consistently meet all customer expectations.

While Newport's replicated mirror business is capable of fabricating replicated mirrors onto conventional glass optics, our specialty lies in fabrication of metal, ceramic, or composite optics that can incorporate integral mounts, adjustments, and other features. By eliminating separate mounting structures and working with materials other than glass, optical systems can be made lighter, more thermally stable, and more rigid, while facilitating assembly and increasing repeatability. Our unique manufacturing processes allow substrate designs that would not otherwise be feasible, and mirror surfaces can be placed in locations that would otherwise be impossible.

Key Benefits of replicated mirrors include the ability to:

  • Include the optical mount as part of the optical component
  • Provide an accurate mounting surface aligned to the optical surface
  • Permit a kinematic adjustment mechanism to be integral to the optical element
  • Eliminate interfaces between the mirror and the mount that can go out of alignment under temperature excursions, vibration, and shock
  • Have their temperature coefficient of expansion matched to the optical bench making the system less susceptible to ambient temperature changes

Solutions Offering

Aspheric Mirrors
Typical optic configurations include on and off axis paraboloids, ellipsoids, and toroids. High-accuracy aspheric elements can be produced in prototype through volume production quantities at a fraction of the cost associated with making similar products by conventional methods. Surfaces and coatings suitable for use in the deep UV through the far IR can be produced in virtually any accuracy, and substrates can incorporate integral mounts and kinematic adjustments if necessary. Many aspheric components can be designed to simply “bolt in place”. With this type of optic / mount design, there is no additional alignment or adjustment necessary for assembly into an instrument.

Retroreflectors & Arrays
Truly monolithic individual hollow corner-cube and roof prisms offer bolt-in-place mounting, real thermal stability, and extreme resistance to shock and vibration, making them ideally suited for use in field applications, motion systems, and aerospace environments. Retroreflectors can be manufactured in virtually any shape substrate.
Large elements up to 70 mm in aperture are not uncommon. Arrays of multiple hollow prisms can be assembled and mounted in protective enclosures for long range sensing applications, and accuracies of the retroreflectors can be tailored to fit requirements of the application. Typical return beam accuracy values range from 2 arc sec. for precision applications to 30 arc sec. for less demanding applications.

Flat and Spherical Mirrors
Although flat and spherical glass optics are widely available at relatively low costs, in many cases these types of optics are difficult and expensive to obtain in custom shapes, sizes, and materials, and they are typically not available with integral mounting features. Focusing on the idea that improved fit, form, and function often constitute a better overall value, Newport Corporation offers the opportunity to upgrade components from standard off-the-shelf items to items that are specifically designed for an application, at costs that resemble those of the “standard” items.

Lightweight and Low Inertia Optics
The density of the substrate is an important consideration when the weight of an optic is critical. The material's density must be considered in relation to its Young's modulus. A low density combined with a high Young's modulus yields minimum component weight and minimum inertia. Our experience using a diverse list of substrate materials including Silicon Carbide, Aluminum, Beryllium, and others to fabricate replicated optics provides a unique capability unavailable to traditional optics manufacturers.

Telescopes, Microscope Objectives, and Other Assemblies
In addition to fabricating individual components, Newport Corporation can provide complete optical assemblies fabricated using replicated mirrors and other optical components. Custom reflective telescopes, microscope objectives, beam expanders, and “lateral transfer” devices are routinely manufactured, assembled, and tested at our facility. Designs range from relatively simple spherical systems to complex aspherical systems.

Optics for Multi-Pass Cells
For analytical instrument applications, our ability to provide multiple or “complex” mirror surfaces on a single substrate with repeatable, bolt-in-place alignment makes instrument assembly and field service an easy process. Special stainless steel mirrors allow cells to be used in extreme environments without the danger of adhesives breaking down at high temperature or under exposure to corrosives. Mirrors for White Cells, Herriott Cells, and even custom aspheric-based cell designs can be produced at very competitive prices.

Material Selection

Almost any material that epoxy will adhere to can be used as a replica substrate. However, the surface accuracy and stability of the mirror will depend completely on that choice of substrate material. We routinely fabricate replicated mirrors on the following substrates:

Aluminum Aluminum Oxide Beryllium Fused Silica Glass
Miralloy Silicon Silicon Carbide Stainless Steel Titanium

Coatings

The majority of our replicated mirrors are coated with Bare Gold. In addition to Bare Gold coatings, we produce mirrors with Bare Aluminum, Protected Aluminum, Bare Silver, and Protected Silver.

Specialized Measurement Capabilities

In addition to our capabilities for routine spectral, environmental, mechanical and optical inspection, we have designed and built an integrated measurement system consisting of a phase-shift interferometer coupled with a high-precision coordinate measurement machine. This instrument allows measurement of the relationship between the mounting surface of an optic and its optical surface, referred to as pointing accuracy. This instrument enables pointing accuracy measurements to within 0.00010" to be routinely made.

Custom & OEM Specification Capabilities

Spectral Range200 nm to 15 µm
Reflectance85% to 99% (dependent upon wavelength)
CoatingBare Aluminum, Bare Gold, Protected Aluminum, Protected Silver
Surface QualityE/E (60/40) per MIL-F-48616 (typical); D/C (40/20) or C/B (20/10) achievable
Surface Roughness25 Å (typical)
Coating AdhesionMIL-F-48616
Coating HardnessProtected Aluminum & protected Silver coatings, only; MIL-F-48616 (modified to 0.5 lb.)
Operating Temperature Range-80 °F to 160 °F
Humidity ResistanceMIL-F-48616
Wavefront Distortionλ/2 @ 633 nm (typical) [range from 2λ to λ/8]
Size Range3 mm to 300mm (typical) [3 mm to 65 mm for Hollow Metal Retroreflectors]
Substrate MaterialAluminum, Aluminum Oxide, Beryllium, Fused Silica, Glass, Graphite-Epoxy, Miralloy, Silicon, Silicon Carbide, Stainless Steel, Titanium
[Aluminum and Stainless Steel for Hollow Metal Retroreflectors]

Download Replicated Mirrors Capabilities DataSheet