This invention is directed to a process for manufacturing a lightweight
mirror from a single crystal material, such as single crystal silicon. As
a near perfect single crystal material, single crystal silicon has much
lower internal stress than a conventional material. This means much less
distortion of the optical surface during the light weighting process.
After being ground and polished, a single crystal silicon mirror is light
weighted by removing material from the back side using ultrasonic
machining. After the light weighting process, the single crystal silicon
mirror may be used as-is or further figured by conventional polishing or
ion milling, depending on the application and the operating wavelength.