Fabrication of the Double Shell 2 Laser Targets Via the Bonding of Hemispheres

摘要

This paper discusses techniques used to manufacture a precision meso-scale assembly consisting of machined aerogel and polymer hemispherical shells. Meso-scale manufacturing issues have been identified relating to micro-mechanical machining, part handling, fixturing, assembly, and bonding. Aerogel can be deterministically machined using a depth of cut on the order of a micron to form nearly massless meso-scale structures. Vacuum chucks provide an excellent means of fixturing meso-scale components when machining both internal and external contours. In cases in which the tool exerts a large force or torque on the part, the holding force of the vacuum can be augmented by gluing the workpiece to a sacrificial vacuum chuck. The assembly of meso-scale components is complicated by part alignment and the fragility of the parts. The bonding of the components was one of the crucial steps in the manufacturing plan, and this effort would have benefited from an ability to control the amount of adhesive dispensed with picoliter resolution and place the adhesive on the part with micron-level accuracy.