MOONS is the Multi-Object Optical and Near-IR Spectrograph for ESO's Very Large Telescope. The instrument will use similar to 1000 optical fibres which can be individually aligned to on-sky targets across a field of view of 500 square arcmin. Each fibre is positioned using a dual arm theta-phi fibre positioning unit (FPU). The MOONS metrology system must be able to simultaneously measure the position of each fibre to a high accuracy (similar to 15 micrometres) as well as measuring the orientation of the FPU arms. In this paper, we present a description of photogrammetry-based metrology system design and its implementation in the instrument. We also report on the integration, testing, and performance of the system within the instrument.

Ground-based astronomical instruments have mass limits to ensure they can operate safely and accurately. Reducing the mass of optomechanical structures relieves mass budget for other components, improving the instrument’s performance. Many industries have adopted generative design (GD) and additive manufacturing (AM; 3D printing) to produce lightweight components. This is yet to be implemented in ground-based astronomical instrumentation; this paper aims to provide insight into the advantages and limitations of this approach. The project studied the Extremely Large Telescope (ELT) Mid-infrared Imager and Spectrograph (METIS) threemirror anastigmat (TMA); comparing the conventional, subtractive machined design with GD-AM designs. The TMA was selected due to its bespoke geometry constrained by an optical path, a conventional design which did not consider mass reduction, the size of the part (615mm × 530mm × 525mm) that necessitated a study of different AM methods, and the operational environment (70K & 10−6 Pa). The study created mass-optimised designs of the TMA using topology optimisation and field-driven design. The performance of these designs was analysed using finite element analysis and optical ray tracing. It was found that GD-AM designs pass the required optical, structural and modal requirements, with a greater than 30% weight reduction when compared to the conventional design. The study investigated wire arc additive manufacturing (WAAM), a viable method of manufacturing components of the TMA’s size. To commence the validation of WAAM for cryogenic environments, samples of WAAM aluminium 5356 were created and studied. The internal and external dimensions of two samples were investigated using X-ray computed tomography and the outgassing rate of two sets of three samples were evaluated to quantify the difference between machined and as-built samples.

Lightweight optical manufacture is no longer confined to the conventional subtractive (mill and drill), formative (casting and forging) and fabricative (bonding and fixing) manufacturing methods. Additive manufacturing (AM; 3D printing), creating a part layer-by-layer, provides new opportunities to reduce mass and combine multiple parts into one structure. Frequently, modern astronomical telescopes and instruments, ground- and space-based, are limited in mass and volume, and are complex to assemble, which are limitations that can benefit from AM. However, there are challenges to overcome before AM is considered a conventional method of manufacture, for example, upskilling engineers, increasing the technology readiness level via AM case studies, and understanding the AM build process to deliver the required material properties. This paper describes current progress within a four-year research programme that has the goal to explore these challenges towards creating a strategy for AM adoption within astronomical hardware. Working with early-career engineers, case studies have been undertaken which focus on lightweight AM aluminium mirror manufacture and optical mountings. In parallel, the aluminium AM build parameters have been investigated to understand which combination of parameters results in AM parts with consistent material properties and low defects. Metrology results from two AM case studies will be summarised: the optical characteristics of a lightweighted aluminium mirror intended for in-orbit deployment from a nanosat; and the AM build quality of wire arc additive manufacture for use in an optomechanical housing. Finally, an analysis of how surface roughness from AM mirror samples and build parameters are linked will be discussed.

The Multi Object Optical and Near-infrared Spectrograph (MOONS) instrument is the next generation multi-object spectrograph for the Very Large Telescope (VLT). The instrument combines the high multiplexing capability offered by 1000 optical fibres deployed by individual robotic positioners with a novel spectrograph able to provide both low- and high-resolution spectroscopy simultaneously across the wavelength range 0.64μm - 1.8μm. Powered by the collecting area of the 8-m VLT, MOONS will provide the astronomical community with a world-leading facility able to serve a wide range of Galactic, Extragalactic and Cosmological studies. This paper provides an updated overview of the instrument and its construction progress, reporting on the ongoing integration phase.

Details of a programme to investigate the outgassing rate of additively manufactured (AM) aluminium alloys are presented. AM has significant potential benefits to applications in ground- and space-based instrumentation, particularly in mass optimisation, part consolidation and increased design freedom. However, its use in high-risk projects is often curtailed by lack of heritage and an imperfect understanding of the materials. The programme goal was to address one of the most significant topics preventing wider adoption of AM technology in cryogenic and space-based applications; uncertainty about material outgassing. The sensitivity of outgassing rates to various key parameters was characterised, including print method, post-processing and geometrical complexity. Correlation of outgassing rates against other measurable properties, such as sample porosity and surface roughness, was also investigated via the use of X-ray computed tomography and profilometry. Finally, the test apparatus, experimental design and implications of the findings on design and process control are discussed.

MOONS is the Multi-Object Optical and Near-IR Spectrograph to be mounted at a Nasmyth focus at the Very Large Telescope. The instrument is equipped with 1000 fibres configured over a field of view of ~500 square arcmin using theta-phi fibre positioning units (FPUs). The MOONS metrology system must accurately determine the position of the fibres in the focal plate, providing fast feedback to the instrument control software during operations. The returned fibre positions can be used for calibrations of the FPUs or fast system recovery after a power loss. If required, the system can also be used for calculating fine adjustments of the fibre positions during acquisition. In this paper, a description of the system design, implementation, and testing in the MOONS focal plate are provided. The presented system has high potential for adaptation to a variety of astronomical instrument applications during integration, testing, and operation stages.

MOONS (Multi-Object Optical and Near-infrared Spectrograph) is a third-generation visible and near-infrared spectrograph for the ESO Very Large Telescope, currently nearing the end of the assembly phase. The three channel spectrograph is fed via a fibre positioning module (FPM) which configures the location of 1001 fibres. The robotic fibre positioning units (FPUs) have been jointly developed by the UK Astronomy Technology Centre (UKATC) and MPS Microsystems (MPS) and provide a high-performance multiplexed focal plane with excellent transmission characteristics. An overview of the as-built mechanisms and supporting infrastructure is presented, with details on the extensive calibration process carried out. The integration process to date will be described, including a discussion of key lessons learned.