2mm x 2mm mirror array construction - can you help?

[simonlhill]

TL;DR

Hi. What is a good process for constructing a 500mm x 500mm array of 2mm x 2mm mirrors (i.e. 250 x 250 mini mirrors) all at preset angles?

I’m looking to construct a 500mm x 500mm array of 2mm x 2mm mirrors (i.e. 250 x 250 mini mirrors). Each tiny mirror is at a different angle. The mirror angles are all preset - there is no need for any to move - such that the entire panel can be designed on a CAD package.

I am thinking this could be made using some kind of ultra high-resolution 3D printer, but the issue is the mirror finish must be perfect. So every 2mm x 2mm mirror needs a perfect square mirror finish. It can’t be approximate or curve at the edges of each mini mirror or the panel won’t produce the required optical effect.

Might anyone be able to please recommend a process for constructing this? Or perhaps a company that does this type of work?

 

[renormalize]

TL;DR Summary: Hi. What is a good process for constructing a 500mm x 500mm array of 2mm x 2mm mirrors (i.e. 250 x 250 mini mirrors) all at preset angles?

You might get some ideas from this: https://gfx.cs.princeton.edu/pubs/Fuchs_2013_DAF/cgf12201.pdf

 

[DaveC426913]

At the risk of second guessing your project needs, is there any reason why you have to have it designed beforehand? What if you calibrated it with first light?

For example - and I'm sure I'm way off case here - coat your .5m x .5m base with plaster or epoxy putty or some such, place the mirrors in the wet stuff and then shine light on it one at a time to ensure its reflecting perfectly. Let it dry.

Do you care what the angles are, as long as every mirror points where it needs to?