Additive manufacturing of ATHENA’s large optical bench by direct energy deposition

The large class science mission NewATHENA, rescoped by the European Space Agency (ESA) in November 2023, will explore the hot and energetic universe using advanced X-ray technology. The key components of the telescope will be hundreds of Silicon Porous Optics (SPO) modules arranged in an optical bench with a diameter of around 2.7 metres. Considering the overall size, the delicate cell structure and the high aspect ratio in combination with the material-related challenges of Ti6Al4V, additive manufacturing using Direct Energy Deposition (DED) is a promising alternative to conventional processing. In addition to discussing fundamental challenges (e.g. shielding), the development of a highperformance hybrid DED process and associated equipment for robust long-term production will be presented. The developed end-to-end manufacturing approach will be verified by manufacturing and analysing test specimens, geometric demonstrators and representative large breadboards.