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HARMONI is the adaptive optics assisted, near-infrared and visible light integral field spectrograph for the Extremely Large Telescope (ELT). A first light instrument, it provides the work-horse spectroscopic capability for the ELT. As the project approaches its Final Design Review milestone, the design of the instrument is being finalized, and the plans for assembly, integration and testing are being detailed. We present an overview of the instrument's capabilities from a user perspective, provide a summary of the instrument's design, including plans for operations and calibrations, and provide a brief glimpse of the predicted performance for a specific observing scenario. The paper also provides some details of the consortium composition and its evolution since the project commenced in 2015.

The size and complexity of ground-based astronomy instrumentation is continuously increasing in order to make most efficient use of the existing and new facilities. The logic of this trend is clear, since the high cost of building and maintaining telescopes leads to high demand for their use, maximising the science output is essential. Instrument multiplex and operational modes are therefore ever-increasing. In highly complex instruments, it can be difficult to interpret the meaning of the term “failure” since the loss of individual channels or modes is not the same as a total loss of science capability. In this paper we explore the relationship between the instrument reliability and the delivered science. We also discuss the need to incorporate a good understanding of the reliability in the instrument design. We consider the difference between the inherent availability of the instrument, the operational availability and the scientific output. At the UKATC we have developed a process and set of tools to analyse an instrument design to determine both the inherent and operational availability using a combination of Failure Mode, Effect and Criticality Analysis (FMECA), Reliability Diagrams, and Fault Tree Analysis. These can then be considered in terms of the instrument productivity to determine strategies for redundancy, maintenance and repair. We also review the state of reliability analysis within the ground-based community and compare it with the requirements for space astronomical instrumentation. The methodology and tools developed are intended to be compliant with the requirements for space products.

Additive manufacturing (AM; 3D printing) is a fabrication process that builds an object layer-upon-layer and promotes the use of structures that would not be possible via subtractive machining. Prototype AM metal mirrors are increasingly being studied in order to exploit the advantage of the broad AM design-space to develop intricate lightweight structures that are more optimised for function than traditional open-back mirror lightweighting. This paper describes a UK Space Agency funded project to design and manufacture a series of lightweighted AM mirrors to fit within a 3U CubeSat chassis. Six AM mirrors of identical design will be presented: two in aluminium (AlSi10Mg), two in nickel phosphorous (NiP) coated AlSi10Mg, and two in titanium (Ti64). For each material mirror pair, one is hand-polished and the other is diamond turned. Metrology data, surface form error and surface roughness, will be presented to compare and contrast the different materials and post-processing methods. To assess the presence of porosity, a frequent concern for AM materials, X-ray computed tomography measurements will be presented to highlight the location and density of pores within the mirror substrates; methods to mitigate the distribution of pores near the optical surface will be described. As a metric for success the AlSi10Mg + NiP and AlSi10Mg mirrors should be suitable for visible and infrared applications respectively.

Design for additive manufacture (AM; 3D printing) is significantly different than design for subtractive machining. Although there are some limitations on the designs that can be printed, the increase in the AM design-space removes some of the existing challenges faced by the traditional lightweight mirror designs; for example, sandwich mirrors are just as easy to fabricate as open-back mirrors via AM, and they provide an improvement in structural rigidity. However, the ability to print a sandwich mirror as a single component does come with extra considerations; such as orientation upon the build plate and access to remove any temporary support material. This paper describes the iterations in optimisation applied to the lightweighting of a small, 84mm diameter by 20mm height, spherical concave mirror intended for CubeSat applications. The initial design, which was fabricated, is discussed in terms of the internal lightweighting design and the design constraints that were imposed by printing and post-processing. Iterations on the initial design are presented; these include the use of topology optimisation to minimise the total internal strain energy during mirror polishing and the use of lattices combined with thickness variation i.e. having a thicker lattice in strategic support locations. To assess the suitability of each design, finite element analysis is presented to quantify the print-through of the lightweighting upon the optical surface for a given mass reduction.