Dataset: Modelling and optimisation of rapid tow shearing for composite reflective mirrors in space-based laser communication systems

Lightweight, stable mirrors are essential for space laser communication, requiring low mass, high stiffness, and reliable in-orbit performance. However, few studies compare design, manufacturing, and optical behaviour under the same conditions. This study presents a full design–manufacture–validation approach for a 0.50 m carbon-fibre mirror. Two designs are compared: a straight-fibre laminate and a variable-stiffness laminate made using Rapid Tow Shearing (RTS). Simulations evaluate launch loads, temperature changes, and moisture effects, while manufacturing distortion is also predicted. Both designs meet stiffness requirements (>140 Hz) with strong safety margins. The straight-fibre design reaches ~153 Hz, while the RTS design achieves ~145 Hz with ~11% lower mass. Thermal deformation is similar (~68–69 µm RMS). Moisture effects are smaller but slightly higher in RTS (~22.7 µm vs ~16.7 µm). Manufacturing distortion is comparable (~90–100 µm RMS). Experiments confirm these results. Overall, thermal stability depends mainly on laminate properties. RTS enables lighter mirrors without reducing performance, making it promising for space optics, though manufacturing effects remain important.