Hexagonal cutting of pre-polished circular segments is one of the critical process step in the manufacturing of ELT-M1 mirrors. This enables edge-to-edge optical performance, and precise mechanical references used to align the segment during operation of the segmented primary mirror. This paper presents the novel technology developed by Safran REOSC to guarantee fast and precise referencing of all critical features, hexagonal shaping, edge sensor interface machining, cutouts handling, and throughput over one segment per day. We will analyse the machining performance over 100 mirrors, and the effect of cutting on optical surface.
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