Executive Summary
Astravon delivers sub-nanometre surface precision reflective optics through a fully integrated manufacturing platform encompassing material engineering, ultra-precision fabrication, coating, and metrology. Its vertically integrated, closed-loop process architecture enables deterministic control of surface figure, roughness, and coating-induced stress at scales required for advanced aerospace, deep space, and high-energy optical systems.
The company’s capabilities support large-aperture (Φ50–800 mm), lightweight, thermally stable mirrors with RMS surface accuracy down to 0.05–0.1 nm and roughness below 0.1 nm. Through proprietary technologies—including adaptive ion beam figuring (A-IBF), magnetorheological composite polishing (MRF-CMP), low-stress ion beam sputtering coatings, and sub-nanometre in-situ metrology—Astravon achieves consistent, scalable production of optics meeting or exceeding global top-tier performance benchmarks.
These capabilities position Astravon as a competitive manufacturer alongside established leaders such as ZEISS and Zygo, supporting mission-critical applications in aerospace, high-energy laser systems, and EUV-class optical platforms.
Sub-Nanometre Precision Reflective Optics for Aerospace and High-Energy Systems
Astravon is a manufacturer specialising in sub-nanometre surface precision mirrors, with vertically integrated capabilities spanning material engineering, ultra-precision fabrication, coating, and metrology. Our manufacturing platform is designed to meet the stringent requirements of aerospace deep space exploration, high-energy laser systems, and EUV-class optical systems.
For aerospace applications, particularly deep space missions, Astravon supports Φ300–500 mm class mirrors (flat, spherical, and aspherical) with requirements including lightweight structures, ultra-low thermal expansion, and long-term orbital stability. These systems demand deterministic surface control at sub-nanometre levels under variable thermal and mechanical conditions. Astravon’s manufacturing approach directly addresses these constraints.
We operate within a highly specialised global supply landscape dominated by a limited number of manufacturers. Through proprietary process integration and stable production scalability, Astravon has established competitive capability in high-end optical fabrication.
Precision Reflective Optics
Integrated Manufacturing Architecture
Astravon’s production methodology follows a fully closed-loop architecture based on four tightly coupled processes:
- Substrate material modification
- Ultra-precision machining
- Optical coating
- Sub-nanometre inspection
This vertically integrated approach ensures deterministic control of surface figure and roughness at every stage.
Closed-loop manufacturing architecture for sub-nanometre optical mirrors
Substrate Engineering for Aerospace Environments
Substrate material performance defines the achievable precision envelope and environmental stability. Astravon develops customised material modification processes for fused silica and silicon carbide (SiC), targeting aerospace requirements such as:
- Thermal expansion coefficients approaching 5×10⁻⁸/°C, comparable to materials from Schott and Corning
- Enhanced specific stiffness and reduced density for lightweight mirror structures
- Optimised thermal conductivity for orbital thermal gradients
These modifications enable stable precision under long-duration space operation and launch-induced stress conditions.
Lightweight mirror substrate architecture for thermally stable aerospace applications
Ultra-Precision Fabrication Process
Astravon employs a deterministic multi-stage fabrication workflow:
Custom substrate modification → ductile regime grinding (<30 nm depth) → ring polishing → MRF-CMP → A-IBF
Key technologies include:
1. Magnetorheological Composite Polishing (MRF-CMP)
- Combines magnetorheological finishing (MRF) and chemical mechanical polishing (CMP)
- Enables rapid convergence of surface figure whilst maintaining ultra-low roughness
- Real-time parameter adjustment (magnetic field, dwell time, feed rate) via in-situ metrology
MRF-CMP hybrid polishing mechanism enabling deterministic surface correction and ultra-smooth finishing
2. Adaptive Ion Beam Figuring (A-IBF)
- Non-contact, stress-free finishing using Ar⁺ ion sputtering
- Closed-loop adaptive control with real-time error correction
- 30% improvement in processing efficiency over conventional IBF
- Capable of sub-nanometre figure correction and angstrom-level roughness
Adaptive ion beam figuring with real-time feedback for sub-nanometre surface error correction
Process Performance Progression:
- Initial grinding: sub-micron accuracy
- Ring polishing: PV <50 nm
- MRF-CMP: PV <5–10 nm, RMS <0.5–0.8 nm
- A-IBF final stage: sub-nanometre accuracy
Surface error convergence from grinding to A-IBF final correction.
Optical Coating for High-Energy and Space Applications
Astravon’s coating system is optimised for both optical performance and structural stability:
- Ion Beam Sputtering (IBS) deposition of Ta₂O₅/SiO₂ and HfO₂/SiO₂ multilayers
- Coating stress controlled within 30–50 MPa
- Prevention of post-coating surface distortion
- Reflectivity up to 99.97% at 1064 nm
- Laser damage threshold: 35–40 J/cm²
This combination is critical for high-energy laser systems and spaceborne optics exposed to prolonged radiation and thermal cycling.
Closed-Loop Metrology and Digital Twin Integration
Precision assurance is achieved through an integrated inspection system:
- In-situ metrology accuracy: 0.03–0.08 nm (RMS)
- Power Spectral Density (PSD) analysis for full spatial frequency characterisation
- Digital twin modelling for real-time process optimisation
- 60% reduction in polishing cycles
Environmental stabilisation includes:
- ±0.1°C thermal control
- Cleanroom processing
- Stress-free fixturing and ageing
These measures ensure long-term dimensional stability in orbit.
Achieved Technical Performance
Astravon’s production mirrors meet or exceed global top-tier standards:
Surface Figure Accuracy
- RMS: 0.05–0.1 nm
- PV: ≤ λ/100 (λ=632.8 nm)
- Fully compliant with EUV-class requirements (e.g. systems from ASML)
Surface Roughness
- Ra: 0.06–0.09 nm
- Minimises scattering for high-energy optical paths
Coating Performance
- Stress: 30–50 MPa
- Reflectivity: 99.92–99.98% (visible/NIR)
- Laser damage threshold: 35–40 J/cm²
Size and Geometry Range
- Diameters: Φ50–800 mm
- Compatible with flat, spherical, and aspherical optics
Metrology Accuracy
- 0.03–0.08 nm RMS detection capability
Scalable Manufacturing for Mission-Specific Requirements
Astravon provides differentiated process routes based on precision requirements:
- RMS 0.5–1 nm
- Substrate modification + grinding + ring polishing + MRF
- Optimised for high-throughput production
- RMS 0.2–0.5 nm
- Incorporates A-IBF shaping
- Suitable for aerospace and medium-power laser systems
- RMS <0.2 nm (sub-angstrom level)
- A-IBF + CMP + low-stress coating + ultra-precision inspection
- Enables stable mass production at 0.05–0.1 nm RMS
Outlook: Sub-Ångström Precision for Next-Generation Space Optics
Astravon is advancing towards sub-angstrom surface control with ongoing R&D targeting:
- RMS: 0.03–0.05 nm
- Surface roughness: Ra ≤0.05 nm
This development directly supports next-generation space telescopes, interferometric systems, and high-energy directed systems requiring extreme optical stability and precision.
Summary
Through a fully integrated manufacturing system—spanning material engineering, deterministic fabrication, low-stress coating, and closed-loop metrology - Astravon delivers sub-nanometre precision mirrors at production scale. These capabilities provide critical optical components for aerospace, deep space exploration, and high-energy systems, where performance is defined by stability, precision, and reproducibility under extreme conditions.
Partner with Astravon
Astravon aims to be a trusted engineering partner for optical systems that must perform as intended, throughout their operational life.