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We describe an approach to build an x-ray mirror assembly that can meet Lynx’s requirements of high-angular resolution, large effective area, light weight, short production schedule, and low-production cost. Adopting a modular hierarchy, the assembly is composed of 37,492 mirror segments, each of which measures ∼100 mm × 100 mm × 0.5 mm. These segments are integrated into 611 modules, which are individually tested and qualified to meet both science performance and spaceflight environment requirements before they in turn are integrated into 12 metashells. The 12 metashells are then integrated to form the mirror assembly. This approach combines the latest precision polishing technology and the monocrystalline silicon material to fabricate the thin and lightweight mirror segments. Because of the use of commercially available equipment and material and because of its highly modular and hierarchical building-up process, this approach is highly amenable to automation and mass production to maximize production throughput and to minimize production schedule and cost. As of fall 2018, the basic elements of this approach, including substrate fabrication, coating, alignment, and bonding, have been validated by the successful building and testing of single-pair mirror modules. In the next few years, the many steps of the approach will be refined and perfected by repeatedly building and testing mirror modules containing progressively more mirror segments to fully meet science performance, spaceflight environments, as well as programmatic requirements of the Lynx mission and other proposed missions, such as AXIS.

X-ray astronomy critically depends on X-ray optics. The capability of an X-ray telescope is largelydetermined by the point-spread function (PSF) and the photon-collection area of its mirrors, the same astelescopes in other wavelength bands. Since an X-ray telescope must be operated above the atmosphere inspace and that X-rays reflect only at grazing incidence, X-ray mirrors must be both lightweight and thin, bothof which add significant technical and engineering challenge to making an X-ray telescope. In this paper wereport our effort at NASA Goddard Space Flight Center (GSFC) of developing an approach to making an Xraymirror assembly that can be significantly better than the mirror assembly currently flying on the ChandraX-ray Observatory in each of the three aspects: PSF, effective area per unit mass, and production cost per uniteffective area. Our approach is based on the precision polishing of mono-crystalline silicon to fabricate thinand lightweight X-ray mirrors of the highest figure quality and micro-roughness, therefore, having thepotential of achieving diffraction-limited X-ray optics. When successfully developed, this approach will makeimplementable in the 2020s and 2030s many X-ray astronomical missions that are currently on the drawingboard, including sounding rocket flights such as OGRE, Explorer class missions such as STAR-X andFORCE, Probe class missions such as AXIS, TAP, and HEX-P, as well as large missions such as Lynx.

Future large x-ray astronomy missions require large area and high resolution. The present consensus is to integrate thin, lightweight, segmented mirrors to form a compact but large telescope with high resolution (better than 1 sec). Key technologies: 1) Accurate mirror substrates: polishing high quality mono-crystalline silicon. 2) Stress-free reflective coating: stress-based distortion cancellation. 3) Precise alignment and integration: kinematic mounting and distortion-free bonding. Four-point alignment for quasi-cylindrically symmetric mirrors (segments) - 4-Point alignment: Pitch and yaw angles, image center (X, Y) are controlled by heights of the 4 mount points; Alignment Precision: better than 1 sec; Bonding error: approx. 0.1 micrometers (approx. 1 sec); Current single mirror pair x-ray tested: 3 sec (Half-Power Diameter). Integration into (meta) shell: Shell structure has rotationally defined axis; Interlocking mirrors means lightweight, mechanically strong telescope.

Lynx is a concept under study for prioritization in the 2020 Astrophysics Decadal Survey. Providing orders of magnitude increase in sensitivity over Chandra, Lynx will examine the first black holes and their galaxies, map the large-scale structure and galactic halos, and shed new light on the environments of young stars and their planetary systems. In order to meet the Lynx science goals, the telescope consists of a high-angular resolution optical assembly complemented by an instrument suite that may include a High Definition X-ray Imager, X-ray Microcalorimeter and an X-ray Grating Spectrometer. The telescope is integrated onto the spacecraft to form a comprehensive observatory concept. Progress on the formulation of the Lynx telescope and observatory configuration is reported in this paper.

Angular resolution and photon-collecting area are the two most important factors that determine the power of an X-ray astronomical telescope. The grazing incidence nature of X-ray optics means that even a modest photon-collecting area requires an extraordinarily large mirror area. This requirement for a large mirror area is compounded by the fact that X-ray telescopes must be launched into, and operated in, outer space, which means that the mirror must be both lightweight and thin. Meanwhile the production and integration cost of a large mirror area determines the economical feasibility of a telescope. In this paper we report on a technology development program whose objective is to meet this three-fold requirement of making astronomical X-ray optics: (1) angular resolution, (2) photon-collecting area, and (3) production cost. This technology is based on precision polishing of monocrystalline silicon for making a large number of mirror segments and on the meta-shell approach to integrate these mirror segments into a mirror assembly. The meta-shell approach takes advantage of the axial or rotational symmetry of an X-ray telescope to align and bond a large number of small, lightweight mirrors into a large mirror assembly. The most important features of this technology include: (1) potential to achieve the highest possible angular resolution dictated by optical design and diffraction; and (2) capable of implementing every conceivable optical design, such as Wolter-I, Wolter-Schwarzschild, as well as other variations to one or another aspect of a telescope. The simplicity and modular nature of the process makes it highly amenable to mass production, thereby making it possible to produce very large X-ray telescopes in a reasonable amount of time and at a reasonable cost. As of June 2017, the basic validity of this approach has been demonstrated by finite element analysis of its structural, thermal, and gravity release characteristics, and by the fabrication, alignment, bonding, and X-ray testing of mirror modules. Continued work in the coming years will raise the technical readiness of this technology for use by SMEX, MIDEX, Probe, as well as major flagship missions.

Top-level science goals of the Survey and Time-domain Astrophysical Research eXplorer (STAR-X) include: investigations of most violent explosions in the universe, study of growth of black holes across cosmic time and mass scale, and measure how structure formation heats majority of baryons in the universe. To meet these goals, the field-of-view of the telescope should be about 1 square-degree, the angular resolution should be 5 arc-seconds or below across large part of the field-of-view. The on-axis effective area at 1 KeV should be about 2,000 sq cm. Payload cost and launch considerations limit the outer diameter, focal length, and mass to 1.3 meters, 5 meters, and 250 kilograms, respectively. Telescope design is based on a segmented meta-shell approach we have developed at Goddard Space Flight Center for the STAR-X telescope. The telescope shells are divided into 30-degree segments. Individual telescopes and meta-shells are nested inside each other to meet the effective area requirements in 0.5 - 6.0 KeV range. We consider Wolter-Schwarzschild, and Modified-Wolter-Schwarzschild telescope designs as basic building blocks of the nested STAR-X telescope. These designs offer an excellent resolution over a large field of views. Nested telescopes are vulnerable to stray light problems. We have designed a multi-component baffle system to eliminate direct and single-reflection light paths inside the telescopes. Large number of internal and external baffle vane structures are required to prevent stray rays from reaching the focal plane. We have developed a simple ray-trace based tool to determine the dimensions and locations of the baffles. In this paper, we present the results of our trade studies, baffle design studies, and optical performance analyses of the STAR-X telescope.

Top-level science goals of the Survey and Time-domain Astrophysical Research eXplorer (STAR-X) include: investigations of most violent explosions in the universe, study of growth of black holes across cosmic time and mass scale, and measure how structure formation heats majority of baryons in the universe. To meet these goals, the field-of-view of the telescope should be about 1 square-degree, the angular resolution should be 5 arc-seconds or below across large part of the field-of-view. The on-axis effective area at 1 KeV should be about 2,000 sq cm. Payload cost and launch considerations limit the outer diameter, focal length, and mass to 1.3 meters, 5 meters, and 250 kilograms, respectively. Telescope design is based on a segmented meta-shell approach we have developed at Goddard Space Flight Center for the STAR-X telescope. The telescope shells are divided into 30-degree segments. Individual telescopes and meta-shells are nested inside each other to meet the effective area requirements in 0.5 - 6.0 KeV range. We consider Wolter-Schwarzschild, and Modified-Wolter-Schwarzschild telescope designs as basic building blocks of the nested STAR-X telescope. These designs offer an excellent resolution over a large field of views. Nested telescopes are vulnerable to stray light problems. We have designed a multi-component baffle system to eliminate direct and single-reflection light paths inside the telescopes. Large number of internal and external baffle vane structures are required to prevent stray rays from reaching the focal plane. We have developed a simple ray-trace based tool to determine the dimensions and locations of the baffles. In this paper, we present the results of our trade studies, baffle design studies, and optical performance analyses of the STAR-X telescope.

Optics for the next generation's high-resolution, high throughput x-ray telescope requires fabrication of well-formed lightweight mirror segments and their integration at arc-second precision. Recent advances in the fabrication of silicon mirrors developed at NASA/Goddard prompted us to develop a new method of mirror alignment and integration. In this method, stiff silicon mirrors are aligned quasi-kinematically and are bonded in an interlocking fashion to produce a "meta-shell" with large collective area. We address issues of aligning and bonding mirrors with this method and show a recent result of 4 seconds-of-arc for a single pair of mirrors tested at soft x-rays.

The Survey and Time-domain Astrophysical Research eXplorer (STAR-X) science goals are to discover what powers the most violent explosions in the Universe, understand how black holes grow across cosmic time and mass scale, and measure how structure formation heats the majority of baryons in the Universe. To achieve these goals, STAR-X requires a powerful X-ray telescope with a large field of view, large collecting area, and excellent point spread function. The STAR-X instrument, the X-Ray Telescope Assembly (XTA), meets these requirements using a powerful X-ray mirror technology based on precision-polished single crystal silicon and a mature CCD detector technology. The XTA is composed of three major subsystems: an X-ray Mirror Assembly (MA) of high resolution, lightweight mirror segments fabricated out of single crystal silicon; a Focal Plane Assembly (FPA) made of back-illuminated CCD's capable of detecting X-rays with excellent quantum efficiency; and a composite Telescope Tube that structurally links the MA and FPA. The MA consists of 5,972 silicon mirror segments mounted into five subassemblies called meta-shells. A meta-shell is constructed from an annular central structural shell covered with interlocking layers of mirror segments. This paper describes the requirements, design, and analysis of the XTA subsystems with particular focus on the MA.

We describe an approach to building mirror assemblies for next generation X-ray telescopes. It incorporates knowledge and lessons learned from building existing telescopes, including Chandra, XMM-Newton, Suzaku, and NuSTAR, as well as from our direct experience of the last 15 years developing mirror technology for the Constellation-X and International X-ray Observatory mission concepts. This approach combines single crystal silicon and precision polishing, thus has the potential of achieving the highest possible angular resolution with the least possible mass. Moreover, it is simple, consisting of several technical elements that can be developed independently in parallel. Lastly, it is highly amenable to mass production, therefore enabling the making of telescopes of very large photon collecting areas.

Lightweight and high resolution optics are needed for future space-based x-ray telescopes to achieve advances in high-energy astrophysics. Past missions such as Chandra and XMM-Newton have achieved excellent angular resolution using a full shell mirror approach. Other missions such as Suzaku and NuSTAR have achieved lightweight mirrors using a segmented approach. This paper describes a new approach, called meta-shells, which combines the fabrication advantages of segmented optics with the alignment advantages of full shell optics. Meta-shells are built by layering overlapping mirror segments onto a central structural shell. The resulting optic has the stiffness and rotational symmetry of a full shell, but with an order of magnitude greater collecting area. Several meta-shells so constructed can be integrated into a large x-ray mirror assembly by proven methods used for Chandra and XMM-Newton. The mirror segments are mounted to the meta-shell using a novel four point semi-kinematic mount. The four point mount deterministically locates the segment in its most performance sensitive degrees of freedom. Extensive analysis has been performed to demonstrate the feasibility of the four point mount and meta-shell approach. A mathematical model of a meta-shell constructed with mirror segments bonded at four points and subject to launch loads has been developed to determine the optimal design parameters, namely bond size, mirror segment span, and number of layers per meta-shell. The parameters of an example 1.3 m diameter mirror assembly are given including the predicted effective area. To verify the mathematical model and support opto-mechanical analysis, a detailed finite element model of a meta-shell was created. Finite element analysis predicts low gravity distortion and low sensitivity to thermal gradients.

Lightweight and high resolution optics are needed for future space-based x-ray telescopes to achieve advances in high-energy astrophysics. Past missions such as Chandra and XMM-Newton have achieved excellent angular resolution using a full shell mirror approach. Other missions such as Suzaku and NuSTAR have achieved lightweight mirrors using a segmented approach. This paper describes a new approach, called meta-shells, which combines the fabrication advantages of segmented optics with the alignment advantages of full shell optics. Meta-shells are built by layering overlapping mirror segments onto a central structural shell. The resulting optic has the stiffness and rotational symmetry of a full shell, but with an order of magnitude greater collecting area. Several meta-shells so constructed can be integrated into a large x-ray mirror assembly by proven methods used for Chandra and XMM-Newton. The mirror segments are mounted to the meta-shell using a novel four point semi-kinematic mount. The four point mount deterministically locates the segment in its most performance sensitive degrees of freedom. Extensive analysis has been performed to demonstrate the feasibility of the four point mount and meta-shell approach. A mathematical model of a meta-shell constructed with mirror segments bonded at four points and subject to launch loads has been developed to determine the optimal design parameters, namely bond size, mirror segment span, and number of layers per meta-shell. The parameters of an example 1.3 m diameter mirror assembly are given including the predicted effective area. To verify the mathematical model and support opto-mechanical analysis, a detailed finite element model of a meta-shell was created. Finite element analysis predicts low gravity distortion and low thermal distortion. Recent results are discussed including Structural Thermal Optical Performance (STOP) analysis as well as vibration and shock testing of prototype meta-shells.

High-resolution, high throughput optics for x-ray astronomy entails fabrication of well-formed mirror segments and their integration with arc-second precision. In this paper, we address issues of aligning and bonding thin glass mirrors with negligible additional distortion. Stability of the bonded mirrors and the curing of epoxy used in bonding them were tested extensively. We present results from tests of bonding mirrors onto experimental modules, and on the stability of the bonded mirrors tested in x-ray. These results demonstrate the fundamental validity of the methods used in integrating mirrors into telescope module, and reveal the areas for further investigation. The alignment and integration methods are applicable to the astronomical mission concept such as STAR-X, the Survey and Time-domain Astronomical Research Explorer.

Optical design trades are underway at the Goddard Space Flight Center to define a telescope for an x-ray survey mission. Top-level science objectives of the mission include the study of x-ray transients, surveying and long-term monitoring of compact objects in nearby galaxies, as well as both deep and wide-field x-ray surveys. In this paper we consider Wolter, Wolter-Schwarzschild, and modified Wolter-Schwarzschild telescope designs as basic building blocks for the tightly nested survey telescope. Design principles and dominating aberrations of individual telescopes and nested telescopes are discussed and we compare the off-axis optical performance at 1.0 KeV and 4.0 KeV across a 1.0-degree full field-of-view.

Lightweight and high resolution optics are needed for future space-based X-ray telescopes to achieve advances in high-energy astrophysics. The Next Generation X-ray Optics (NGXO) team at NASA GSFC is nearing mission readiness for a 10 arc-second Half Power Diameter (HPD) slumped glass mirror technology while laying the groundwork for a future 1-2 arc-second technology based on polished silicon mirrors. Technology Development Modules (TDMs) have been designed, fabricated, integrated with mirrors segments, and extensively tested to demonstrate technology readiness. Tests include X-ray performance, thermal vacuum, acoustic load, and random vibration. The thermal vacuum and acoustic load environments have proven relatively benign, while the random vibration environment has proven challenging due to large input amplification at frequencies above 500 Hz. Epoxy selection, surface preparation, and larger bond area have increased bond strength while vibration isolation has decreased vibration amplification allowing for space launch requirements to be met in the near term. The next generation of TDMs, which demonstrates a lightweight structure supporting more mirror segments, is currently being fabricated. Analysis predicts superior performance characteristics due to the use of E-60 Beryllium-Oxide Metal Matrix Composite material, with only a modest cost increase. These TDMs will be larger, lighter, stiffer, and stronger than the current generation. Preliminary steps are being taken to enable mounting and testing of 1-2 arc-second mirror segments expected to be available in the future. A Vertical X-ray Test Facility (VXTF) will minimize module gravity distortion and allow for less constrained mirror mounts, such as fully kinematic mounts. Permanent kinematic mounting into a modified TDM has been demonstrated to achieve 2 arc-second level distortion free alignment.

Lightweight and high resolution mirrors are needed for future space-based X-ray telescopes to achieve advances in high-energy astrophysics. The slumped glass mirror technology in development at NASA GSFC aims to build X-ray mirror modules with an area to mass ratio of approx.17 sq cm/kg at 1 keV and a resolution of 10 arc-sec Half Power Diameter (HPD) or better at an affordable cost. As the technology nears the performance requirements, additional engineering effort is needed to ensure the modules are compatible with space-flight. This paper describes Flight Mirror Assembly (FMA) designs for several X-ray astrophysics missions studied by NASA and defines generic driving requirements and subsequent verification tests necessary to advance technology readiness for mission implementation. The requirement to perform X-ray testing in a horizontal beam, based on the orientation of existing facilities, is particularly burdensome on the mirror technology, necessitating mechanical over-constraint of the mirror segments and stiffening of the modules in order to prevent self-weight deformation errors from dominating the measured performance. This requirement, in turn, drives the mass and complexity of the system while limiting the testable angular resolution. Design options for a vertical X-ray test facility alleviating these issues are explored. An alternate mirror and module design using kinematic constraint of the mirror segments, enabled by a vertical test facility, is proposed. The kinematic mounting concept has significant advantages including potential for higher angular resolution, simplified mirror integration, and relaxed thermal requirements. However, it presents new challenges including low vibration modes and imperfections in kinematic constraint. Implementation concepts overcoming these challenges are described along with preliminary test and analysis results demonstrating the feasibility of kinematically mounting slumped glass mirror segments.

Future X-ray astronomy missions demand thin, light, and closely packed optics which lend themselves to segmentation of the annular mirrors and, in turn, a modular approach to the mirror design. The modular approach to X-ray Flight Mirror Assembly (FMA) design allows excellent scalability of the mirror technology to support a variety of mission sizes and science objectives. This paper describes FMA designs using slumped glass mirror segments for several X-ray astrophysics missions studied by NASA and explores the driving requirements and subsequent verification tests necessary to qualify a slumped glass mirror module for space-flight. A rigorous testing program is outlined allowing Technical Development Modules to reach technical readiness for mission implementation while reducing mission cost and schedule risk.

To provide observations to support current research efforts in high energy astrophysics. future X-ray telescope designs must provide matching or better angular resolution while significantly increasing the total collecting area. In such a design the permanent mounting of thin and lightweight segments is critical to the overall performance of the complete X-ray optic assembly. The thin and lightweight segments used in the assemhly of the modules are desigued to maintain and/or exceed the resolution of existing X-ray telescopes while providing a substantial increase in collecting area. Such thin and delicate X-ray segments are easily distorted and yet must be aligned to the arcsecond level and retain accurate alignment for many years. The Next Generation X-ray Optic (NGXO) group at NASA Goddard Space Flight Center has designed, assembled. and implemented new hardware and procedures mth the short term goal of aligning three pairs of X-ray segments in a technology demonstration module while maintaining 10 arcsec alignment through environmental testing as part of the eventual design and construction of a full sized module capable of housing hundreds of X-ray segments. The recent attempts at multiple segment pair alignment and permanent mounting is described along with an overview of the procedure used. A look into what the next year mll bring for the alignment and permanent segment mounting effort illustrates some of the challenges left to overcome before an attempt to populate a full sized module can begin.

Advancements in X-ray astronomy demand thin, light, and closely packed thin optics which lend themselves to segmentation of the annular mirrors and, in turn, a modular approach to the mirror design. The functionality requirements of such a mirror module are well understood. A baseline modular concept for the proposed International X-Ray Observatory (IXO) Flight Mirror Assembly (FMA) consisting of 14,000 glass mirror segments divided into 60 modules was developed and extensively analyzed. Through this development, our understanding of module loads, mirror stress, thermal performance, and gravity distortion have greatly progressed. The latest progress in each of these areas is discussed herein. Gravity distortion during horizontal X-ray testing and on-orbit thermal performance have proved especially difficult design challenges. In light of these challenges, fundamental trades in modular X-ray mirror design have been performed. Future directions in module X-ray mirror design are explored including the development of a 1.8 m diameter FMA utilizing smaller mirror modules. The effect of module size on mirror stress, module self-weight distortion, thermal control, and range of segment sizes required is explored with advantages demonstrated from smaller module size in most cases.

The flight mirror assemblies (FMA) for X-ray telescopes similar to that of the International X-ray Observatory (IXO) concept consist of several thousands of individual mirror segments. The size, shape, and location of these mirrors affect many characteristics of the telescope design. Mission requirements among other factors in turn restrict mirror segment parameters such as thickness, axial- length, azimuthal span, and mass density. This paper provides an overview of the critical relationships relating to mirror segment size and configuration throughout the design and analysis of an X-ray mirror assembly. A computational analysis is presented in the form of ray tracing pairs of thin X-ray mirror segments of varying sizes aligned in gravity and supported using kinematic constraints with corresponding self weight distortions calculated using finite element analysis (FEA). The work in this paper may be used as a starting point for determining mirror segment sizes for X-ray missions like that of IXO and beyond.

The Soft X-Ray Telescope (SXT) modules are the fundamental focusing assemblies on NASA's next major X-ray telescope mission, the International X-Ray Observatory (IXO). The preliminary design and analysis of these assemblies has been completed, addressing the major engineering challenges and leading to an understanding of the factors effecting module performance. Each of the 60 modules in the Flight Mirror Assembly (FMA) supports 200-300 densely packed 0.4 mm thick glass mirror segments in order to meet the unprecedented effective area required to achieve the scientific objectives of the mission. Detailed Finite Element Analysis (FEA), materials testing, and environmental testing have been completed to ensure the modules can be successfully launched. Resulting stress margins are positive based on detailed FEA, a large factor of safety, and a design strength determined by robust characterization of the glass properties. FEA correlates well with the results of the successful modal, vibration, and acoustic environmental tests. Deformation of the module due to on-orbit thermal conditions is also a major design driver. A preliminary thermal control system has been designed and the sensitivity of module optical performance to various thermal loads has been determined using optomechanical analysis methods developed for this unique assembly. This design and analysis furthers the goal of building a module that demonstrates the ability to meet IXO requirements, which is the current focus of the IXO FMA technology development team.

The International X-ray Observatory (IXO) is a new collaboration between NASA, ESA, and JAXA which is under study for launch in 2020. IXO will be a large 6600 kilogram Great Observatory-class mission which will build upon the legacies of the Chandra and XMM-Newton X-ray observatories. It combines elements from NASA's Constellation-X program and ESA's XEUS program. The observatory will have a 20-25 meter focal length, which necessitates the use of a deployable instrument module. Currently the project is actively trading configurations and layouts of the various instruments and spacecraft components. This paper will provide a snapshot of the latest observatory configuration under consideration and summarize the observatory from the mechanical engineering perspective.