Feasibility study of solid surface subreflector production techniques

The principal effort was to study technical feasibility and cost aspects of the production technique of spin forming a subreflector reflective surface to a desired surface of revolution, back the surface with fiberglass to stabilize it sufficiently so that it may be machined to the target surface tolerance of .008 inches Root Mean Square (RMS) with a goal of .003 inches RMS. To verify this production technique, analyses was performed to define the production procedure. A price estimate for a 150 inch diameter subreflector for a 34 meter cassegrain antenna. During this feasibility study, numerous production processes were evaluated theoretically as production approaches for single surface, non-welded subreflectors. The first successful was the principal process of spin forming the reflective surface, backing with fiberglass and machining to a final contour. The second successful process was spin forming or bump forming a thicker reflective surface, with an integral (welded in) structure as a backing and machining the mounting pads and reflector to a final configuration.