Wilsnack, ChristophChristophWilsnackMoritz, JulianeJulianeMoritzReutlinger, ArndArndReutlingerEberle, SebastianSebastianEberleStepien, LukasLukasStepienLopez, ElenaElenaLopezBrückner, FrankFrankBrücknerLeyens, ChristophChristophLeyens2024-04-302024-04-302023https://publica.fraunhofer.de/handle/publica/467034This study explores the use of a combination of the hypereutectic aluminum-silicon alloy AlSi40 and electroless nickel (NiP) for optical mirrors in space-borne instruments. The combination of AlSi40 and NiP offers a solution to the trade-offs between optical performance, structural integrity, manufacturing time and price that traditional materials used for optical space applications have. AlSi40 is processable by additive technologies like Laser Powder Bed Fusion (LPBF), which allows the design and fabrication of optical components with optimized internal structures (e.g. lattice structures) resulting in increased stiffness-to-mass ratio of the component, which is crucial for space applications. The process chain, including parameter development and material characterization, was conducted and a demonstrator mirror was printed and tested under representative operational conditions. The study also includes the transfer process of the parameters and the experimental conditions between several AM machines, to ensure the scalability and reproducibility of the process.enLaser Powder Bed FusionAdditive ManufacturingQuality Assurance; SpaceAlSi40hyper-eutectic alloyDDC::600 Technik, Medizin, angewandte Wissenschaftenconference paper