Twenty-two institutions have collaborated on the project to build the next generation, advanced technology, ground-based solar telescope. To date, the solar telescope has passed its preliminary design review through the use of scale models made from selective laser sintering technology.
 This early version of the completed Solar Telescope model consisted of twelve assembled SLS parts. Key pieces could be removed to expose internal areas. |
Solid Concepts, Inc.
As yet another era of discoveries about the sun is upon us, it is necessary that we observe the subtle ways that it affects life on Earth. To do this, it is important to observe the sun and its magnetic activities at higher spectral, spatial, and temporal resolutions.
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The Advanced Technology Solar Telescope (ATST) project was initiated to study these mechanisms for solar activity beyond the capability of current telescopes. For example, modern telescopes can only resolve features the size of Texas, whereas the ATST will use adaptive optics to resolve features as small as counties that are 30 to 70 km (18-42 miles) across, and possibly smaller.
The project has successfully passed its preliminary design review, representing a major milestone in moving the project forward. To clearly identify and communicate critical design issues to the review panel, the ATST team required 1/75th scale models of the proposed project. These design prototypes would only be completed once. Additional design changes would be completed on computers only.
 This photo is of an SLS model showing the cutaway view of the internal structure found inside the ATST building. In this version of the design, the telescope assembly will be mounted on the top platform. A rotating lab is located inside the pier and can be seen directly underneath the telescope mount. |
Solid Concepts was chosen to produce the needed models directly from digital CAD renderings provided by the ATST team. The CAD designs were easily converted to STL files for a total of twelve parts that were produced.
The twelve parts were used to create a single larger version of the model that included a number of key pieces that could be removed in order to expose critical internal areas of the design. The different versions of the model provided unique views of the overall design through various cutaways, and provided stand-alone models of specific key components.
The SLS (Selective Laser Sintering) process, used to prototype the parts, allows models to be produced in a very short period of time. It is an additive manufacturing process that builds three-dimensional parts by using a laser to fuse a powdered material layer by layer.
Designs are created in 3D CAD data in STL format. Solid Concepts can also start with a simple sketch of the design and one of their engineers will turn it into the proper format. The STL file is then mathematically sliced in software to form 2D cross-sections of the part. From there the parts are scanned and sintered using CO2 laser energy. New layers are sintered (fused) to the preceding layers until the part is completed.
While SLS production began as a way to build prototype parts like the ATST model, it is also being used to produce manufactured parts for end-use. Industries now using the system for production parts include aerospace, automotive, consumer, and medical.
Because SLS parts and models are rugged enough to provide workable models in industrial applications, it was obvious that it was the perfect system to use for the ATST model components.
Working with a Project Engineer from Solid Concepts, ATST team members provided continual approvals of important design modifications to the models. Along the way, components such as railings and stairs had to be strengthened because they could not be sized down to a full 1/75th scale without risking the possibility of breaking.
An important benefit of working with a Project Engineer is using their experience and expertise to identify issues long before they become a problem, which further reduced the time needed for concept to part.
 One of the individual components of the ATST model, the mount assembly has gone through several design changes. Here is a CAD drawing that is slightly different than the component shown. |
One of the key benefits of Rapid Prototyping is the identification of design changes early in the process prior to significant financial investments taking place. In the case of the ATST, the Preliminary Design Review team made a number of helpful suggestions regarding elements of the design, and the project members immediately went to work implementing the recommendations.
The latest information on the ATST project is that the President’s fiscal 2009 budget plan has requested $2.5 million to reduce design risks. It also moved the ATST to NSF’s (National Science Foundation) Major Research Equipment and Facilities Construction account.
Ultimately, the ATST Project Team hopes to see its completed telescope placed at the Maui Space Surveillance Complex atop Haleakala, Maui, HI.