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Revealing the Hidden Universe with Full-shell X-ray Optics at NASA MSFC


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The study of X-ray emission from astronomical objects reveals secrets about the Universe at the largest and smallest spatial scales. Celestial X-rays are produced by black holes consuming nearby stars, emitted by the million-degree gas that traces the structure between galaxies, and can be used to predict whether stars may be able to host planets hospitable to life. X-ray observations have shown that most of the visible matter in the universe exists as hot gas between galaxies and have conclusively demonstrated that the presence of “dark matter” is needed to explain galaxy cluster dynamics, that dark matter dominates the mass of galaxy clusters, and that it governs the expansion of the cosmos.

X-ray observations also enable us to probe mysteries of the Universe on the smallest scales. X-ray observations of compact objects such as white dwarfs, neutron stars, and black holes allow us to use the Universe as a physics laboratory to study conditions that are orders of magnitude more extreme in terms of density, pressure, temperature, and magnetic field strength than anything that can be produced on Earth. In this astrophysical laboratory, researchers expect to reveal new physics at the subatomic scale by conducting investigations such as probing the neutron star equation of state and testing quantum electrodynamics with observations of neutron star atmospheres. At NASA’s Marshall Space Flight Center, a team of scientists and engineers is building, testing, and flying innovative optics that bring the Universe’s X-ray mysteries into sharper focus.

Purple, blue and white swirls overlaid with a pattern of orange dashed lines in the center.
A composite X-ray/Optical/Infrared image of the Crab Pulsar. The X-ray image from the Chandra X-ray Observatory (blue and white), reveals exquisite details in the central ring structures and gas flowing out of the polar jets. Optical light from the Hubble Space Telescope (purple) shows foreground and background stars as pinpoints of light. Infrared light from the Spitzer Space Telescope (pink) traces cooler gas in the nebula. Finally, magnetic field direction derived from X-ray polarization observed by the Imaging X-ray Polarimetry Explorer is shown as orange lines.
Magnetic field lines: NASA/Bucciantini et al; X-ray: NASA/CXC/SAO; Optical: NASA/STScI; Infrared: NASA-JPL-Caltech

Unlike optical telescopes that create images by reflecting or refracting light at near-90-degree angles (normal incidence), focusing X-ray optics must be designed to reflect light at very small angles (grazing incidence). At normal incidence, X-rays are either absorbed by the surface of a mirror or penetrate it entirely. However, at grazing angles of incidence, X-rays reflect very efficiently due to an effect called total external reflection.  In grazing incidence, X-rays reflect off the surface of a mirror like rocks skipping on the surface of a pond.

A classic design for astronomical grazing incidence optics is the Wolter-I prescription, which consists of two reflecting surfaces, a parabola and hyperbola (see figure below). This optical prescription is revolved around the optical axis to produce a full-shell mirror (i.e., the mirror spans the full circumference) that resembles a gently tapered cone. To increase the light collecting area, multiple mirror shells with incrementally larger diameters and a common focus are fabricated and nested concentrically to comprise a mirror module assembly (MMA).

Focusing optics are critical to studying the X-ray universe because, in contrast to other optical systems like collimators or coded masks, they produce high signal-to-noise images with low background noise. Two key metrics that characterize the performance of X-ray optics are angular resolution, which is the ability of an optical system to discriminate between closely spaced objects, and effective area, which is the light collecting area of the telescope, typically quoted in units of cm2. Angular resolution is typically measured as the half-power diameter (HPD) of a focused spot in units of arcseconds.  The HPD encircles half of the incident photons in a focused spot and measures the sharpness of the final image; a smaller number is better. 

Cutaway image of a tube with black and green lines passing through it and converging on a gray square.
Schematic of a full-shell Wolter-I X-ray optic mirror module assembly with five concentrically nested mirror shells. Parallel rays of light enter from the left, reflect twice off the reflective inside surface of the shell (first off the parabolic segment and then off the hyperbolic segment), and converge at the focal plane.
NASA MSFC

NASA Marshall Space Flight Center (MSFC) has been building and flying lightweight, full-shell, focusing X-ray optics for over three decades, always meeting or exceeding angular resolution and effective area requirements. MSFC utilizes an electroformed nickel replication (ENR) technique to make these thin full-shell X-ray optics from nickel alloy.

X-ray optics development at MSFC began in the early 1990s with the fabrication of optics to support NASA’s Advanced X-ray Astrophysics Facility (AXAF-S) and then continued via the Constellation-X technology development programs. In 2001, MSFC launched a balloon payload that included two modules each with three mirrors, which produced the first focused hard X-ray (>10 keV) images of an astrophysical source by imaging Cygnus X-1, GRS 1915, and the Crab Nebula.  This initial effort resulted in several follow-up missions over the next 12 years, and became known as the High Energy Replicated Optics (HERO) balloon program.

In 2012, the first of four sounding rocket flights of the Focusing Optics X-ray Solar Imager (FOXSI) flew with MSFC optics onboard, producing the first focused images of the Sun at energies greater than 5 keV. In 2019 the Astronomical Roentgen Telescope X-ray Concentrator (ART-XC) instrument on the Spectr-Roentgen-Gamma Mission launched with seven MSFC-fabricated X-ray MMAs, each containing 28 mirror shells. ART-XC is currently mapping the sky in the 4-30 keV hard X-ray energy range, studying exotic objects like neutron stars in our own galaxy as well as active galactic nuclei, which are spread across the visible universe. In 2021, the Imaging X-ray Polarimetry Explorer (IXPE), flew and is now performing extraordinary science with an MSFC-led team using three, 24-shell MMAs that were fabricated and calibrated in-house.

Most recently, in 2024, the fourth FOXSI sounding rocket campaign launched with a high-resolution MSFC MMA. The optics achieved 9.5 arcsecond HPD angular resolution during pre-flight test with an expected 7 arcsecond HPD in gravity-free flight, making this the highest angular resolution flight observation made with a nickel-replicated X-ray optic. Currently MSFC is fabricating an MMA for the Rocket Experiment Demonstration of a Soft X-ray (REDSoX) polarimeter, a sounding rocket mission that will fly a novel soft X-ray polarimeter instrument to observe active galactic nuclei. The REDSoX MMA optic will be 444 mm in diameter, which will make it the largest MMA ever produced by MSFC and the second largest replicated nickel X-ray optic in the world.

Left: two team members in white protective gear standing in a large tube; the individual in front is standing behind a large cylinder embedded in a rectangular case. Right: A team member in blue protective gear working on a large tubular-shaped device in a lab.
Scientists Wayne Baumgartner (left, crouched) and Nick Thomas (left, standing) calibrate an IXPE MMA in the MSFC 100 m Beamline. Scientist Stephen Bongiorno (right) applies epoxy to an IXPE shell during MMA assembly.
NASA MSFC

The ultimate performance of an X-ray optic is determined by errors in the shape, position, and roughness of the optical surface. To push the performance of X-ray optics toward even higher angular resolution and achieve more ambitious science goals, MSFC is currently engaged in a fundamental research and development effort to improve all aspects of full-shell optics fabrication.

Given that these optics are made with the Electroformed Nickel Replication technique, the fabrication process begins with creation of a replication master, called the mandrel, which is a negative of the desired optical surface. First, the mandrel is figured and polished to specification, then a thin layer of nickel alloy is electroformed onto the mandrel surface. Next, the nickel alloy layer is removed to produce a replicated optical shell, and finally the thin shell is attached to a stiff holding structure for use.

Each step in this process imparts some degree of error into the final replicated shell. Research and development efforts at MSFC are currently concentrating on reducing distortion induced during the electroforming metal deposition and release steps. Electroforming-induced distortion is caused by material stress built into the electroformed material as it deposits onto the mandrel. Decreasing release-induced distortion is a matter of reducing adhesion strength between the shell and mandrel, increasing strength of the shell material to prevent yielding, and reducing point defects in the release layer.

Additionally, verifying the performance of these advanced optics requires world-class test facilities. The basic premise of testing an optic designed for X-ray astrophysics is to place a small, bright X-ray source far away from the optic. If the angular size of the source, as viewed from the optic, is smaller than the angular resolution of the optic, the source is effectively simulating X-ray starlight. Due to the absorption of X-rays by air, the entire test facility light path must be placed inside a vacuum chamber.

At MSFC, a group of scientists and engineers operate the Marshall 100-meter X-ray beamline, a world-class end-to-end test facility for flight and laboratory X-ray optics, instruments, and telescopes. As per the name, it consists of a 100-meter-long vacuum tube with an 8-meter-long, 3-meter-diameter instrument chamber and a variety of X-ray sources ranging from 0.25 – 114 keV. Across the street sits the X-Ray and Cryogenic Facility (XRCF), a 527-meter-long beamline with an 18-meter-long, 6-meter-diameter instrument chamber. These facilities are available for the scientific community to use and highlight the comprehensive optics development and test capability that Marshall is known for.

Within the X-ray astrophysics community there exist a variety of angular resolution and effective area needs for focusing optics. Given its storied history in X-ray optics, MSFC is uniquely poised to fulfill requirements for large or small, medium- or high-angular-resolution X-ray optics. To help guide technology development, the astrophysics community convenes once per decade to produce a decadal survey. The need for high-angular-resolution and high-throughput X-ray optics is strongly endorsed by the National Academies of Sciences, Engineering, and Medicine report, Pathways to Discovery in Astronomy and Astrophysics for the 2020s.In pursuit of this goal, MSFC is continuing to advance the state of the art in full-shell optics. This work will enable the extraordinary mysteries of the X-ray universe to be revealed.

Project Leads

Dr. Jessica Gaskin and Dr. Stephen Bongiorno, NASA Marshall Space Flight Center (MSFC)

Sponsoring Organizations

The NASA Astrophysics Division supports this work primarily through the Internal Scientist Funding Model Direct Work Package and competed solicitations. This work is also supported by the Heliophysics Division through competed solicitations, as well as by directed work from other government entities.

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      Last Updated Apr 02, 2025 Editor Marty McCoy Contact Laura Betz laura.e.betz@nasa.gov Related Terms
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      How It Works
      Where telescopes like NASA’s Hubble and James Webb space telescopes were designed to target small areas of space in detail, SPHEREx is a survey telescope and takes a broad view. Combining its results with those of targeted telescopes will give scientists a more robust understanding of our universe.
      The observatory will map the entire celestial sky four times during its two-year prime mission. Using a technique called spectroscopy, SPHEREx will collect the light from hundreds of millions of stars and galaxies in more wavelengths any other all-sky survey telescope.
      Track the real-time location of NASA’s SPHEREx space observatory using the agency’s 3D visualization tool, Eyes on the Solar System. When light enters SPHEREx’s telescope, it’s directed down two paths that each lead to a row of three detectors. The observatory’s detectors are like eyes, and set on top of them are color filters, which are like color-tinted glasses. While a standard color filter blocks all wavelengths but one, like yellow- or rose-tinted glasses, the SPHEREx filters are more like rainbow-tinted glasses: The wavelengths they block change gradually from the top of the filter to the bottom.
      “I’m rendered speechless,” said Jim Fanson, SPHEREx project manager at JPL. “There was an incredible human effort to make this possible, and our engineering team did an amazing job getting us to this point.”
      More About SPHEREx
      The SPHEREx mission is managed by JPL for the agency’s Astrophysics Division within the Science Mission Directorate at NASA Headquarters. BAE Systems (formerly Ball Aerospace) built the telescope and the spacecraft bus. The science analysis of the SPHEREx data will be conducted by a team of scientists located at 10 institutions in the U.S., two in South Korea, and one in Taiwan. Caltech managed and integrated the instrument. Data will be processed and archived at IPAC at Caltech. The mission’s principal investigator is based at Caltech with a joint JPL appointment. The SPHEREx dataset will be publicly available at the NASA-IPAC Infrared Science Archive. Caltech manages JPL for NASA.
      For more about SPHEREx, visit:
      https://science.nasa.gov/mission/spherex/
      News Media Contact
      Calla Cofield
      Jet Propulsion Laboratory, Pasadena, Calif.
      626-808-2469
      calla.e.cofield@jpl.nasa.gov
      2025-045
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      Last Updated Apr 01, 2025 Related Terms
      SPHEREx (Spectro-Photometer for the History of the Universe and Ices Explorer) Astrophysics Galaxies Origin & Evolution of the Universe The Search for Life The Universe Explore More
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