A scalable rigidized inflatable reflector system for next-generation far-infrared space telescopes

Abstract

Large-aperture space telescopes are fundamentally constrained by launch vehicle fairing volume, motivating the development of deployable inflatable reflectors that can be packaged compactly and inflated on orbit. While inflatable membrane optics offer dramatic gains in areal density and packaging efficiency, their long-term shape stability remains the principal barrier to their use as precision optical surfaces. Rigidization, the transition from a pressurized membrane to a self-supporting structure, is therefore essential for sustained operation. Building on the authors’ previous work on UV resin laminate rigidization, this paper presents the development and characterization of UV-resin rigidizable inflatable laminates fabricated from Mylar substrates impregnated with a photo-initiator based resin system that cures upon ultraviolet exposure. We define the surface stability requirements for operation at infrared wavelengths within the bounds of active wavefront correction, and describe the laminate architecture, rigidization methodology, calibration and metrology processes developed to meet those requirements. The experimental test setup integrates deflectometry and direct collimated source spot measurements to capture the as-deployed and post-cure surface figures of sub-scale specimens, enabling quantitative assessment of root-mean-square surface error, large-scale figure deviations, and high-frequency wrinkling. White light interferometry is used to characterize the surface micro-roughness enhancements as a consequence of the rigidization process. Results are evaluated against correct-ability thresholds for downstream adaptive optics, and the implications for scaling UV-resin rigidization to meter class astronomical reflectors are discussed.