In-space manufacturing of optical lenses: Fluidic Shaping aboard the International Space Station

Abstract: In-space manufacturing technologies are vital for enabling advanced space missions and addressing logistical limitations of space exploration. While additive manufacturing has progressed rapidly, it still falls short of delivering the ultra-smooth surfaces required for optical elements. Fluidic Shaping is a novel method that harnesses surface tension under microgravity to form optical components with exceptionally smooth surfaces. This study demonstrates the feasibility and potential of Fluidic Shaping as a method for manufacturing optical components in space through two experiments performed aboard the International Space Station (ISS) during the Ax-1 mission. The first experiment involved fabricating centimeter-scale polymer lenses, solidifying them via ultraviolet (UV) curing, and analyzing the resultant optics upon their return to Earth. While sub-nanometric surface smoothness was achieved, some polymer lenses displayed unexpected thermo-chemical deformations, indicating complex polymerization dynamics unique to the microgravity environment. In the second experiment, a large-scale, 172 mm diameter water lens was deployed, confirming Fluidic Shaping's scalability and demonstrating basic optical functionality through image analysis. These experiments collectively underline the technique's relevance for both small-scale optics and large-aperture applications. Our results highlight critical considerations for future research, including optimizing polymerization processes and refining liquid-handling methods to advance practical, in-space optical manufacturing capabilities.