Hi Big AL!
Thanks for your feedback! You are correct, it is indeed crucial to position each and every mirror right in its exact place for the best geometry! We did a lot of research and testings in oder to get the optimum shape.
Now, after a looooong and complex development process we engineered a simple yet highly precise production process. For producing the mirror assembly we have used different very precise machines and tools, including laser cutting and thermal plastic deformation.
Once the mirror is produced, you simply have to inflate it and it will always get its pre-formed shape. The amount of pressure inside the mirror does not significantly change the shape or the focal length, as we are using (almost) non-elastic foils.
So even though the production process is sophisticated, the application itself for the user is as easy as inflating an air matress. It was one of our main goals during development stage transforming this high-tech principle into a convenient and simple product so literally everybody is able to use it.
Thanks again for passing on that info. Without feed back like that we wouldn't be as far along in our development!
Cheers Mate