Partners: ÉireComposites & Mbryonics
Funding: Disruptive Technologies Innovation Fund (DTIF)
Disclaimer: The consortium have received € 4m from Enterprise Ireland under the DTFI Call 5
Project Background
Advanced optics are becoming increasingly vital for a wide range of high-tech applications across global markets. These solutions, which involve components like mirrors, lenses, and prisms, are critical for optical data collection and high data processing rates facilitated by photonics. However, there is a significant gap in volume manufacturing solutions for high specification mirrors, especially for freeform mirrors. The need for affordable Optical Inter-Satellite Links (OISLs) that can be produced in large quantities—thousands of units per year—has become pressing. The key challenge is the cost and manufacturing bottleneck associated with the mirrors and optics inside the optical antenna.
Traditional manufacturing of high specification mirrors is labor-intensive and costly. Producing a single 100mm mirror can take over a day and cost around €30,000, with typically three mirrors required per OISL. Given the target unit cost of $100,000 for large-scale constellations and the annual volume requirements in the tens of thousands, there is an urgent need to develop advanced manufacturing processes to disrupt and revolutionize the classical optics sector.
Freeform-OPTIX Objectives
The FreeForm-OPTIX project aims to transform the classical mirror manufacturing industry by creating novel process chains within two pilot lines for high specification mirrors. The project will enable SMEs like Mbryonics and ÉireComposites to establish highly automated industrial production lines. These new production capabilities will support sectors with emerging applications, including space optics, wireless optical communications for 5G, freeform optics for medical technologies, wearables, and high numerical aperture UV lithography for semiconductor machines. The overarching goal is to establish a new advanced optics manufacturing sector in Ireland and disrupt the traditional optics manufacturing industry, positioning Ireland as a global leader in producing high-value products for new and emerging high-tech markets.
Project Partners
The FreeForm-OPTIX consortium includes key partners: ÉireComposites and Mbryonics. ÉireComposites provides expertise in advanced materials and manufacturing processes, while Mbryonics brings innovative solutions and capabilities in optical technologies. Together, these partners will drive the development of automated production lines and advanced manufacturing techniques.
Expected Impacts
The FreeForm-OPTIX project is expected to deliver substantial economic, environmental, and societal benefits. It will create 125 jobs in the rural Connemara Gaeltacht area and boost annual exports to €15 million within five years, supporting SDG 8, Decent Work and Economic Growth. The project will advance SDG 9, Industry, Innovation, and Infrastructure by enhancing manufacturing innovation and enabling scalable production of freeform mirrors, thus positioning SME partners for higher supply chain roles and promoting sustainable industrial growth. By adopting green methodologies that reduce waste, reuse materials, lower energy requirements, and facilitate on-demand manufacturing, the project supports SDG 12, Responsible Consumption and Production, and promotes a circular economy. Additionally, the project will contribute to SDG 13, Protect the Planet, by significantly reducing CO2 emissions and material usage compared to traditional methods, aiding in global climate change mitigation efforts.