Production of astronomical instruments

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Precision for the world's largest telescope

The powerful five-axis machining center G750 from Grob produces large and complex components for the astronomical instruments of the Extremely Large Telescope, ELT, which is scheduled to go into operation in 2028, with maximum stability and precision.

The Extremely Large Telescope, ELT. © Nova/coarse

In 2028, the world's largest optical telescope is due to go into operation in Chile: the Extremely Large Telescope (ELT) with a mirror diameter of 39 meters. It will study planets and image distant galaxies in greater detail than ever before. Nova is leading an international consortium that is building one of the first instruments to be attached to this telescope. The manufacture of these massive astronomical instruments requires the production of large aluminum parts with extraordinary precision in the micrometer range. The existing milling machine was no longer able to meet these requirements. "The components we used to produce were much smaller than the instruments we had to manufacture for the ELT. For this reason, we needed a larger milling machine," explains Niels Tromp, System Engineer at Nova.

Milling machine from Grob

High-precision milled components from Nova for the ELT. © Nova/coarse

As a state-funded institution, Nova was bound by a tendering process for the new machine. "One of our main requirements was to produce components with the same tolerance as before in the range of ten to 20 micrometres, and over a distance of more than one meter," emphasizes Niels Tromp, System Engineer at Nova. After the tender, the company first looked at the available options. After extensive evaluation, four manufacturers were shortlisted. Further selection procedures revealed that only one provider met all the requirements. The G750 from Grob was chosen. The G750 is a powerful milling machining center for high precision and efficiency, providing the stability and accuracy required to produce the complex parts for the ELT's astronomical instruments.

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Optimum integration into the production process

To minimize potential risks, the machine was housed in a facility with stable temperature control. Thermal expansion can affect the production process, so it was important to create an environment that would enable the precise machining of components. In addition, the G750 was combined with a state-of-the-art coordinate measuring machine, which was placed in an ISO Class 6 clean room environment. This combination enabled Nova to measure and assemble the high-precision components produced on the universal machine. The facility that houses the milling machine is unique and allows Nova to control the entire design and manufacturing process in-house. "Without this facility, Nova would not be able to build instruments for the largest optical telescope in the world," emphasizes Thomas Wijnen, Instrumentation Coordinator at Nova.

Integration of the milling machine into the production processes

With the G750 five-axis universal machine, customers in industrial production achieve first-class results in the milling of large workpieces. © Nova/coarse

The integration of the G750 into the manufacturing process has brought decisive advantages. Nova's monolithic design philosophy, which minimizes the number of interfaces and combines many individual components into a single part, has helped to reduce alignment and tolerance issues. The milling machine makes it possible to manufacture the components with exceptional precision, which was crucial for the construction of the astronomical instruments.

Large-format workpiece for the telescope. © Nova/coarse

The system with the integrated G750 shows that it is also suitable for the high-precision industry. By controlling the entire design and manufacturing process internally, many risks can be minimized, resulting in greater efficiency and quality of the manufactured parts.

Five-axis universal machining center

The Nova Institute, an association of the four leading university astronomy institutes in the Netherlands. © Nova/coarse

"I can confidently say that the G750 from Grob has more than met our expectations and that the components we are now producing are fully in line with the specifications and even exceed what we expected from the manufacture," states Thomas Wijnen, Instrumentation Coordinator at Nova. With the G750 five-axis universal machine, industrial manufacturing customers achieve first-class results in the milling of large workpieces. With working paths of 1,000 millimetres in the X-axis, 1,100 millimetres in the Y-axis and 1,175 millimetres in the Z-axis, large components can be produced with precision.

Nova researches the stars

Nova is an internationally renowned association of the four leading university astronomy institutes in the Netherlands. The aim is to participate in world-class astronomical facilities and to make leading contributions to astronomy research. In view of the construction of the Extremely Large Telescope (ELT) in Chile, the largest optical telescopes in the world, NOVA took over the leadership of an international consortium that is developing one of the first instruments for this telescope.

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