Hubble Space Telescope
Origin of the problem

A commission headed by Lew Allen, director of the Jet Propulsion Laboratory, was established to determine how the error could have arisen. The Allen Commission found that a reflective null corrector, a testing device used to achieve a properly shaped non-spherical mirror, had been incorrectly assembled—one lens was out of position by 1.3 mm (0.051 in). During the initial grinding and polishing of the mirror, Perkin-Elmer analyzed its surface with two conventional refractive null correctors. However, for the final manufacturing step (figuring), they switched to the custom-built reflective null corrector, designed explicitly to meet very strict tolerances. The incorrect assembly of this device resulted in the mirror being ground very precisely but to the wrong shape. During fabrication, a few tests using conventional null correctors correctly reported spherical aberration. But these results were dismissed, thus missing the opportunity to catch the error, because the reflective null corrector was considered more accurate.

The commission blamed the failings primarily on Perkin-Elmer. Relations between NASA and the optics company had been severely strained during the telescope construction, due to frequent schedule slippage and cost overruns. NASA found that Perkin-Elmer did not review or supervise the mirror construction adequately, did not assign its best optical scientists to the project (as it had for the prototype), and in particular did not involve the optical designers in the construction and verification of the mirror. While the commission heavily criticized Perkin-Elmer for these managerial failings, NASA was also criticized for not picking up on the quality control shortcomings, such as relying totally on test results from a single instrument.
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