Production of the 4.26 m ZERODUR mirror blank for the Advanced Technology Solar telescope (ATST)

The Daniel K. Inouye Solar Telescope (DKIST, formerly the Advanced Technology Solar Telescope, ATST) will be the most powerful solar telescope in the world. It is currently being built by the Association of Universities for Research in Astronomy (AURA) in a height of 3000 m above sea level on the mountain Haleakala of Maui, Hawaii. The primary mirror blank of diameter 4.26 m is made of the extremely low thermal expansion glass ceramic ZERODUR® of SCHOTT AG Advanced Optics. The DKIST primary mirror design is extremely challenging. With a mirror thickness of only 78 to 85 mm it is the smallest thickness ever machined on a mirror of 4.26 m in diameter. Additionally the glassy ZERODUR® casting is one of the largest in size ever produced for a 4 m class ZERODUR® mirror blank. The off axis aspherical mirror surface required sophisticated grinding procedures to achieve the specified geometrical tolerance. The small thickness of about 80 mm required special measures during processing, lifting and transport. Additionally acid etch treatment was applied to the convex back-surface and the conical shaped outer diameter surface to improve the strength of the blank. This paper reports on the challenging tasks and the achievements on the material property and dimensional specification parameter during the production of the 4.26 m ZERODUR® primary mirror blank for AURA.