Multi-layer casting of polymeric mirrors for visible wavelength applications

Abstract

A process for producing flat or parabolic mirrors for visible wavelength applications is described and includes the steps of casting onto a substrate of substantially the selected mirror shape a liquid polymer resin in multiple cured layers whereby the last applied layer has the selected mirror shape unaffected by topography flaws in the surface of the substrate. A reflective coating may then be applied to the last applied and cured resin layer.

1. A process for producing a polymeric mirror for visible wavelength applications, comprising the steps of:
 (a) providing a source of liquid polymeric material;  
 (b) providing a substrate for supporting a mirrored surface of preselected shape;  
 (c) casting a first layer of said liquid polymeric material onto said substrate and curing said first layer; and said first layer; and  
 (d) casting at least one additional layer of said liquid polymeric material onto said first layer, and curing each said additional layer prior to casting a subsequent layer thereon.  
 
     
     
       2. The process of  claim 1  wherein said substrate is substantially flat. 
     
     
       3. The process of  claim 1  wherein said substrate is substantially parabolic in shape. 
     
     
       4. The process of  claim 3  further comprising the step of rotating said substrate about an axis through said parabolic shape during cure of said polymeric material whereby said liquid polymeric material assumes the said parabolic shape of said substrate. 
     
     
       5. The process of  claim 1  wherein said liquid polymeric material is cast onto said substrate by one of pouring, spraying, powder melt and film melt. 
     
     
       6. The process of  claim 1  wherein each said layer is cast to a thickness of about 0.001 to 2 mm. 
     
     
       7. The process of  claim 1  further comprising the step of applying a metallic reflective coating onto the last applied and cured layer of said polymeric material.