Marcell Westsik | Searcharxiv

arXiv2026

Exploring generative design AI tools for astronomical instrumentation: a CubeSat chassis case study

Generative design artificial intelligence (AI) tools are currently used in multiple scientific fields, yet their adoption in mechanical engineering computer-aided design (CAD) remains limited due to a lack of disseminated case studies, limited availability of accessible tools, insufficient training in CAD data, the absence of universal editable file formats and more. Mechanical design for astronomical instrumentation faces increasing complexity in thermal, vibrational, and mechanical requirements alongside tight project deadlines. This paper presents a practical evaluation of an AI and FEA based generative design tool applied to chassis design for the Active Deployable Optical Telescope (ADOT) CubeSat mission. Our analysis showcases the workflow steps including the setting of design, manufacturing and objective constraints. This study also shows the clear benefits of these types of tools, especially in the early brainstorming stages of multi-constrained mechanical structures, while also highlighting clear limitations like their black-box nature, the non-manufacturing-ready state of the results, and the time-consuming setup, limiting the tangible gain of these tools to high-value mechanical components.

astro-ph.IM↗

arXiv2026

Laser Remelting for Reduced Porosity on Additively Manufactured Aluminium Mirrors

Additively manufactured (AM) AlSi10Mg mirrors are fabricated through laser powder bed fusion (LPBF), allowing the use of complex geometries such as lattices and organic structures that enable high mass reduction while maintaining mechanical stiffness. Micron-sized pores that cause optical scatter may form during LPBF as a consequence of deviations from the optimal processing window, particularly from laser energy input and scan strategy. This work proposes a laser remelting strategy aimed at reducing porosity; standard LPBF build steps automatically alternate with laser remelting passes, where previously deposited material is remelted during fabrication. Laser remelting is evaluated through fabricating 10 mm proof-of-concept cubes. Following single point diamond turning (SPDT), optical measurements characterised surface roughness and identified surface artefacts. The best-performing AlSi10Mg remelted cube exhibited no pores within sampled regions and achieved 6.4 nm average surface roughness, comparable to a conventionally manufactured RSA 6061 control cube (5.8 nm). Driven by these results, AM 52 mm diameter secondary sandwich mirrors were manufactured using LPBF and laser remelting. These incorporate an optimised diamond TPMS lattice to achieve a 50% mass reduction while accommodating design for AM considerations. Unlike the cube study, the optical surface of the remelted mirror after SPDT exhibited residual porosity and 11.8 nm average surface roughness. These results show that while the proof-of-concept confirmed the viability of laser remelting in reducing porosity within simple geometries, optimisation of the LPBF and SPDT processes are required to translate the benefits of laser remelting to lightweight AlSi10Mg AM mirrors.

physics.optics↗