Newton STFC-NARIT : Towards freeform optics manufacturing capabilities in Thailand for Space and Astronomical applications

Lead Research Organisation: Durham University
Department Name: Physics

Abstract

Thailand is quickly building its astronomical instrumentation development capacity. In the past decade, National Astronomical Research Institute of Thailand (NARIT) has actively grown its workforce on two fronts: astronomical instrumentation for the Thai National Observatory (TNO) and space instrumentation and satellite development through the Thailand Satellite Consortium (TSC; NARIT, the Siam Photon Laboratory and the Geo-informatics and Space Technology Development Agency). TSC is currently building its first "made in Thailand" satellites - a major national milestone. However, one limitation restricts independent advancement on these fronts: to access innovative technologies, Thailand must rely on developed countries for hardware and associated support, and this is particularly true for optical design and manufacture, which depend heavily on heritage, expertise and specialised equipment.

NARIT desires to remove this barrier and invest in a future Thailand optical manufacturing capability, which will help to drive Thailand's economy and industries in line with the Thailand 4.0 economic model. This project proposes a programme that provides both knowledge exchange and a joint Thai-UK research project, to upskill Thai academics and engineers in conventional and additive optical manufacturing methods, to enable internal capability and impact within wider disciplines.

The project will enable the transfer of 2 key technologies to Thailand:

- Freeform optics are identified as a NARIT research priority; they are novel, versatile optical elements with no axis of rotation or symmetry. Increasingly, they are used in pioneering optical designs offering abundant new opportunities for optical designers. The emergence of these new types of surfaces has been very much in pace with the development of Single Point Diamond Turning (SPDT).
- Metal additive manufacturing (MAM), which has significant potential when applied to optical manufacturing and freeform optics in particular. MAM is the process of building a component layer-upon-layer in metal and it is commonly used low count bespoke parts. MAM prints a near-net shape without material removal, formers, or shape manipulation, which define conventional manufacture

Combining Metal Additive Manufacturing with optical freeform manufacturing has, therefore, a lot of potential for the production of pioneering astronomical and space instrumentation. SPDT and MAM have also a strong potential to be spun out into business ventures to stimulate the local economy.

Planned Impact

The proposal "Towards freeform optics manufacturing capabilities in Thailand for Space and Astronomical applications" is a multi-disciplinary project, which will endeavour to promote the economic development and welfare of Thailand while maximising the academic impact of the work. This will be achieved by transferring conventional and additive manufacturing skills to Thailand leading to high academic and technological impact.

Academic impact: Metal mirror fabrication and metrology key knowledges will be transferred to NARIT staff during the precision manufacturing and metrology training held in Durham for a week and during 3 placements for a Thai researcher. An open access scientific paper, co-authoring all of the UK and Thailand participants will be published and the project's scientific work will be presented in an international conference.

Economic impact: Maximisation of the economic impact will be achieved by defining a clear roadmap to the market and by understanding how the local to regional economy could benefit from skills gained during this project. The project will explore business opportunities offering services of the 2 main technologies (Conventional and Additive Metal optics precision manufacturing) locally and in the wider South East Asia. An important aspect of the project will be to look at how freeform optics and additive manufacturing capability in Thailand could benefit other scientific and commercial areas such as in Healthcare (contact lenses freeform inserts, Additive manufacturing of metal implants), Automotive and Aeronautics. A workshop on Astronomical & Space instrumentation will be organised in Thailand at the end of the project, to encourage networking, industrial engagement and scientific dissemination.


Societal impact: Outreach will be central to the project activities with participation at some NARIT exhibitions in regional observatories, Siam Physics Conference and Thai Physics festivals. The impact goal is to highlight the importance of STEM careers in technology development in the hope to encourage more Thai school children to study a STEM subject for further education.
 
Description The award allowed NARIT to grow its optical manufacturing capabilities, and lead to a STFC-IAA.
Sector Aerospace, Defence and Marine,Manufacturing, including Industrial Biotechology
Impact Types Economic

 
Title Method for extracting form distortion from Finite Element analysis output and modelling the error as optical aberration 
Description The method consists in importing a Finite Element Analysis file (as displacement of a meshgrid) and models how the displacement can be converted into optical aberrations such as Legendre/Chebychev or Zernike polynomials using a least square fitting method. 
Type Of Material Technology assay or reagent 
Year Produced 2021 
Provided To Others? No  
Impact This method will help mechanical design engineers to verify that the integrated mounting interface of mirrors does not add in any stress to the part and therefore affect the optical performance of the system. 
 
Title Novel algorithm for computing tool path to produce blazed freeform gratings on a 5 axis diamond machine 
Description We have developed an algorithm which computes the tool path to produce a freeform grating on a 5 axis diamond machine keeping at the same time, the full control of the bazed angle. This tool can be used to produce diffraction gratings on a curved surface, adding optical power on top of the diffractive function of the grating. The blazed angle maximizes the efficiency of the diffracted wave in a specific diffraction order and help to make spectrograph more compact and efficient. 
Type Of Material Improvements to research infrastructure 
Year Produced 2018 
Provided To Others? No  
Impact This research tool has enabled a collaboration with the industry (which is at an early stage at the moment) Horiba Scientific with a commercial impact for the industry. 
 
Title Space mirror form optimisation based on Zernike polynomial 
Description The method offers a way of correcting manufacturing errors based on a measurement made by optical interferometry. The method consists in modelling the error with Zernike polynomials and exporting them into a machining file to optimise the form of the part that is being machined. The plan is to incorporate this methodology into an open source python package that will be made freely available. 
Type Of Material Technology assay or reagent 
Year Produced 2021 
Provided To Others? No  
Impact The method optimises the form of the optics being manufactured up to a residual error of 10 to 15 nm RMS. This method will help industries or institutes working in precision optics by speeding up the process of form optimisation and will help to deliver better optics working over a broader wavelength range. The resulting optics will be able to work at shorter wavelength than before. 
 
Description Collaboration with Oxford University (Atmospheric, Oceanic and Planetary Physics) 
Organisation University of Oxford
Department Atmospheric, Oceanic and Planetary Physics
Country United Kingdom 
Sector Academic/University 
PI Contribution My team and I have developped and implement novel strategies for optimal manufacturing of the freeform mirrors.
Collaborator Contribution The Atmospheric, Oceanic and Planetary Physics at Oxford University have led the construction of one instrument on the optical payload.
Impact - manufacturing of a set of 5 flight model freeform mirrors for the Lunar Thermal Mapper
Start Year 2020
 
Description Collaboration with the Intitute of Optics - Saclay France 
Organisation L'Institut d'Optique Graduate School
Country France 
Sector Academic/University 
PI Contribution The project has allowed both Durham University and l'Institut d'Optique to work together on the desgin of the TSC-1 instrument lead by NARIT. My research team is currently contributing to make a prototype for the hyperspectral imager that has been jointly designed by NARIT and lnstitut d'Optique. My team has contributed to provide advices on precision optics and on freeform grating.
Collaborator Contribution L'institut d'Optique is providing advices on the optical design.
Impact The collaboration has just started and we will list the outputs and outcomes in the following years.
Start Year 2021
 
Description Collaboration with the University of California Santa Cruz on a novel concept of Integral Field Spectroscopy. 
Organisation University of California, Santa Cruz
Department GenomeBrowser
Country United States 
Sector Academic/University 
PI Contribution We have optically and mechanically optimised a novel concept of a lenslet-slicer hybrid integral field spectrograph (IFS). Our contribution was to provide feedback on what was possible to make and achieve in term of surface accuracy and design. All of the advice was gained from the work undertaken by this grant. We then have manufactured a prototype and tested it.
Collaborator Contribution UCSC has designed a optical system of a lenslet-slicer hybrid integral field spectrograph (IFS) and has also tested it.
Impact - presentation at SPIE Optical Engineering + Applications, 2021, San Diego, California, United States - publication at Proceedings Volume 11823, Techniques and Instrumentation for Detection of Exoplanets X; 118230E - We are also currently discussing the manufacturing of the SCALES (Santa Cruz Array of Lenslets for Exoplanet Spectroscopy) instrument which will be used at the Keck telescope in Hawaii.
Start Year 2020
 
Description Advertisement of the project on the univerity webpage 
Form Of Engagement Activity Engagement focused website, blog or social media channel
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Public/other audiences
Results and Impact The project has been
Year(s) Of Engagement Activity 2021
URL https://www.durham.ac.uk/departments/academic/physics/news/cfai-helps-develop-a-lunar-thermal-mapper...
 
Description CEOI - Emerging Technologies Workshop - Session Advanced Optics & Deployables 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Other audiences
Results and Impact I was invited on the 21/04/2021 to represent Durham University and give a talk at CEOI - Emerging Technologies Workshop - Session Advanced Optics & Deployables - Virtual meeting : "Benefits of Freeform surfaces for Space Optical Systems".
In this invited talk which was attended by about 100 people, I presented my research on freeform optics and this discussion sparked a lot of questions in the community. The audience was very interested in emerging technology and how freeform surfaces were increasingly being used in novel optical systems.
Year(s) Of Engagement Activity 2021
URL https://ceoi.ac.uk/events/emerging-technologies-challenge-workshop/
 
Description Course material for Space Optics Instrument Design & Technology 2020 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact I provided some course material for an ESA workshop Space Optics Instrument Design & Technology 2020, for the lecture on Metal Optics presented by Fraunhofer IOF's Group Leader on Ultraprecision Manufacturing & Freeform Optics. About 50 international participants attended the course. The project was described in the presentation.
Year(s) Of Engagement Activity 2020
URL http://soidt.org/course2020/
 
Description Durham University Youtube video of the project 
Form Of Engagement Activity Engagement focused website, blog or social media channel
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Public/other audiences
Results and Impact 164 views on 09/03/2023
Year(s) Of Engagement Activity 2022
URL https://www.youtube.com/watch?v=Bg2aOjkulaI
 
Description Facebook Social media project advertisement 
Form Of Engagement Activity Engagement focused website, blog or social media channel
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Public/other audiences
Results and Impact 2700 views for this project advertisment on Facebook.
Year(s) Of Engagement Activity 2022
URL https://www.facebook.com/NARITpage/videos/712399653159937/
 
Description Invited Talk on Emerging Technologies for Earth Observation - CEOI - 2024 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact I gave a presentation on Emerging Technologies for Earth Observation and about 100 people attended it.
Year(s) Of Engagement Activity 2021,2024
URL https://ceoi.ac.uk/events/etcw-2024/
 
Description Manufacturing blazed metallic freeform gratings with commercial machines 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact A workshop focus on Scientific Freeform Optics Projects, Manufacturing Technologies, Freeform Systems & Applications, and Characterization of Freeform Surfaces, where industry and academia were invited to present their latest research topic.
Year(s) Of Engagement Activity 2022
URL https://optonet-jena.de/events/upm2022/
 
Description Newton fund Freeform optics STFC article 
Form Of Engagement Activity Engagement focused website, blog or social media channel
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Public/other audiences
Results and Impact Three UK institutes collaborated on a joint Thai-UK research project to exchange knowledge and upskill Thai academics and engineers in optical manufacturing.
Year(s) Of Engagement Activity 2022
URL https://www.ukri.org/blog/3d-printing-collaboration-between-uk-and-thai-research-institute/
 
Description Workshop on Freeform Optics Applications & Manufacturing for Astronomy & Space Missions - NARIT Chiang Mai Thailand 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact A concise workshop on the emergent field of "Freeform Optics" will introduce you to the entire life cycle of building a freeform surface. The participants will have a rare opportunity to learn and interact with the leading experts in various stages of creating freeform optics, starting from the design and simulation of a freeform surface (e.g., segments of metallic primary mirrors, lens, secondary and tertiary mirrors, image slicers, collimators, focusers, etc.), manufacturing, test and verification, assembly, and real-world applications. Furthermore, there will be a chance for the participants to present their own research, ongoing projects, and ideas via poster and contributed oral presentation as well.
Year(s) Of Engagement Activity 2023
URL https://indico.narit.or.th/event/176/
 
Description YouTube clip produced by NARIT for public engagement in English 
Form Of Engagement Activity Engagement focused website, blog or social media channel
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Public/other audiences
Results and Impact 41 views so far on 09/03/2023
Year(s) Of Engagement Activity 2022
URL https://www.youtube.com/watch?v=GnslBYDqpqU
 
Description YouTube clip produced by NARIT for public engagement in Thai 
Form Of Engagement Activity Engagement focused website, blog or social media channel
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Public/other audiences
Results and Impact 1200 views on 09/03/2023
Year(s) Of Engagement Activity 2022
URL https://www.youtube.com/watch?v=m7nR0Vvenu4