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

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The discussion focuses on constructing a 500mm x 500mm array of 2mm x 2mm mirrors, emphasizing the need for each mirror to have a perfect square finish to achieve the desired optical effect. The original poster is considering using an ultra high-resolution 3D printer but is concerned about the precision required for the mirror surfaces. Suggestions include exploring alternative methods, such as using a plaster or epoxy base to set the mirrors while calibrating their angles with light. There are questions about the necessity of pre-setting the angles versus ensuring each mirror reflects correctly. Overall, the conversation seeks effective processes or companies that can assist in this specific mirror construction project.
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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?
 
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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?
 

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