Lightweight Thermoformed Structural Components and Optics

Zeiders, Glenn W.; Bradford, Larry J.

A technique that involves the use of thermoformed plastics has been developed to enable the design and fabrication of ultra-lightweight structural components and mirrors for use in outer space. The technique could also be used to produce items for special terrestrial uses in which minimization of weight is a primary design consideration. Although the inherent strengths of thermoplastics are clearly inferior to those of metals and composite materials, thermoplastics offer a distinct advantage in that they can be shaped, at elevated temperatures, to replicate surfaces (e.g., prescribed mirror surfaces) precisely. Furthermore, multiple elements can be bonded into structures of homogeneous design that display minimal thermal deformation aside from simple expansion. The design aspect of the present technique is based on the principle that the deflection of a plate that has internal structure depends far more on the overall thickness than on the internal details; thus, a very stiff, light structure can be made from thin plastic that is heatformed to produce a sufficiently high moment of inertia. General examples of such structures include I beams and eggcrates.

Document ID

20110016809

Acquisition Source

Marshall Space Flight Center

Document Type

Other - NASA Tech Brief

External Source(s)

http://www.techbriefs.com/index.php?option=com_staticxt&staticfile=/Briefs/july04/MFS31412.html

Authors

Date Acquired

August 25, 2013

Publication Date

July 1, 2004

Publication Information

Publication: NASA Tech Briefs, July 2004

Subject Category

Report/Patent Number

Distribution Limits

Public

Public Use Permitted.

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20110016809.pdf

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