A aluminum round bar with 1,5m length is cut into 17mm thick slices. Sawing time depending on the bar diameter is 1 min – 4 min per disc. roughing the mirror rear side drilling the center hole turning the center hole inner contour threading M18x0,75 for the ball head assembly nut milling a orientation face, important for coming production steps milling a notch, important for coming production steps and deburring the thread fine feed finish preparing part takeover by removing chips from part and opposite spindle takeover of the part to opposite spindle roughing mirror front side fine feed finish mirror outer diameter After anodizing the part will be placed into the machine again manually. The part will be prepared for the next production step by removing the anodizing layer at the mirror side. The final mirror edge is made with a radius miller. The part is ready for the ultra precision flycut after cleaning. The part is clamped into a vacuum chuck. Ultra-precision flycut is done with two diamond cutting tools driven by a air bearing spindle. The part is moved by a air bearing axle. The machine structural frame is made of granite and very stiff. First roughing with feed of 60µm. Due to tolerances the spherical mirror face made by the cnc-lathe does not match perfectly with contour of the ultra-precision flycut. Second roughing with feed of 60µm. This high speed footage shows how the diamond is cutting in slow motion. The second roughing is now covering the complete area. In a climate controlled environment, this machine is capable to machine with of repeatable accuracy of +/- 200 nm. Final finish with 1µm feed (video speed x6). Final machined mirror face with average surface roughness of 2nm (0,000002mm). Laser marking at front and back sides. In prior to the coating process the highly delicate mirror surface need to be cleaned by using dry ice (CO2). All special machines like this one are developed and built by motogadget. The CO2 stream with -78°C is cooling down the aluminum mirror body. Therefore a hot air stream is preheating the mirror to reduce icing of condensed air humidity. To prevent scratches on the highly sensitive mirror face special tools are used for handling. As preparing the coating process the mirror is now placed into special plate which is acting as a electrode in the plasma chamber. The electrode with mounted mirrors is now placed into the plasma reactor. The cover preventing dust particles to settle on the cleaned mirror surface and will be removed in the very last moment. The mirrors even hanging upside down to prevent particles inside the chamber settle on the mirror surface. Also this plasma coating machine was designed and built by motogadget with help of our project partners. The electrical contact of the electrode is done via a high current vacuum sealed contact in the reactor lid. The lid is made of 22mm thick stainless steel and weights over 160kg. It need to sustain the outside air pressure which here corresponds to an weight equivalent of 8000 kg. The lid movement is done by a 950Nm pneumatic actuator, used normally to open and close big valves in water plants. The inner of the reactor is illuminated by the exited plasma. The color of the emitted light is depending of the involved gases. The coating process requires approx. 2 hours. Coated mirrors are cooling down for 30min. For quality control the thickness of the coating is measured on a regular base. Removing the coated mirrors with a vacuum gripper. Coated mirror, ready for assembly. During final assembly the ball head and the mirror arm are mounted to mirror body.