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A two-stage design methodology is developed to provide launch-level confidence for precision optical space structures in the absence of a fully-integrated system test. It is shown that given both high uncertainty and aggressive performance requirements traditional robust design techniques are not adequate to guarantee success. An extension to robust design is developed that includes the concept of tunability in the cost function. The uncertainty compensation is therefore broken down into two stages: robust design and hardware tuning. The extended robust design is employed during the design stage when uncertainty is high but the parameter space is large. Hardware tuning is used after the components are built, when the performance is known, but only limited adjustments are possible. A representative integrated model is used to demonstrate the extended robust design techniques and provide a comparison to existing methods. It is shown that the new formulation results in a design that is guaranteed to meet requirements through a mixture of design robustness and hardware tuning.
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