Topology Optimization for Additive Manufacturing in Astronomical Optomechanics

Modern astronomical instruments exhibit an exceptional complexity with respect to the first telescopes ever designed. They include dozens of mir-rors and optical components, and the supporting infrastructures count hundreds of elements. These structures must satisfy very strict requirements, since they are designed in such a way to prevent any deformation on the optics, which are expected to degrade the final quality of the acquisitions. This study explores the integration of topology optimization (TO) procedures with additive manufactur-ing (AM) techniques to redesign astronomical optomechanics. The application of AM in the astronomical field is expected to provide significant benefits, such as part consolidation, reduced mass, and enhanced mechanical stability endowed by improved optical performance. This paper presents a practical application of the TOxAM framework to a real-world case study, with the aim to discuss in detail the different operative steps of the design process addressing its challenging fea-tures, which impose significant computational demands and compatibility issues arising from the use of diverse software. Developed as part of a Master Thesis in engineering, this work originates from a collaboration between the Department of DICA at Politecnico di Milano and the Italian National Institute for Astrophysics (INAF).