cosine is developing the hardware and tools needed to manufacture two additional types of Silicon Pore Optics (SPO) mirror modules for ESA’s NewAthena space observatory. The work focuses on rows 3 and 13, extending the manufacturing capabilities needed to build the telescope’s large X-ray mirror.
One mirror, hundreds of modules
NewAthena will study some of the hottest and most energetic phenomena in the Universe, helping scientists understand how black holes grow and how large cosmic structures form and evolve.
To collect and focus X-rays, its mirror will combine hundreds of individual mirror modules arranged in concentric rings, called rows. Each module contains stacks of thin silicon plates that reflect X-rays at shallow angles, directing them towards the telescope’s scientific instruments. The final lens will have a 2.6 m diameter and consist of close to 100 000 mirrors (~300 m2 of polished mirror area).
The modules differ across the mirror. Their dimensions and optical shapes depend on their distance from the centre, so each row requires specific designs and manufacturing tools. Preparing a new row means establishing the capability to manufacture modules for that position within the mirror.
Silicon Pore Optics mirror module
Extending the range of module designs
Much of ESA’s and cosine’s development work has focused on row 8, near the middle of the mirror. More recently, the team has extended this work to rows 1 and 15, addressing the different manufacturing challenges towards the inner and outer edges.
Preparing for rows 3 and 13 will broaden the range of module geometries cosine can produce. This is another step towards establishing manufacturing capabilities across the mirror and preparing for sustained production of NewAthena’s flight optics.
From optical design to assembly and testing
Preparing a new row starts with defining the optical geometry and silicon plate design. Engineers then develop the components, fixtures and tools needed to manufacture, assemble and test its mirror modules.
This work brings together cosine’s development and stack production activities in Sassenheim, the Netherlands, with mirror module assembly and X-ray testing in Berlin, Germany and Barcelona, Spain. Working with ESA and specialist partners is central to this effort. Micronit and Teledyne e2v contribute expertise in silicon plate manufacturing, while Carl-Zeiss supplies the precision mandrels that define the optical shape during stacking.
With NewAthena planned for launch in the late 2030s, cosine and its partners are developing the processes, equipment and facilities needed to deliver its X-ray optics. These capabilities will also provide a foundation for future applications of SPO technology.
About cosine
Founded in 1998, cosine is a world-leading developer of space instrumentation and measurement systems, making the invisible measurable and the complex actionable. Its expertise spans High-Energy Optics, including optics developed for ESA’s future NewAthena X-ray observatory, as well as remote sensing solutions for Earth Observation and planetary science. With over 25 years of experience and advanced cleanroom and assembly facilities across the Netherlands, Germany, and Italy, cosine brings deep scientific and engineering expertise to some of the most demanding missions in space and on Earth.
