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They typically consist of a mirror substrate with PZT electrodes bonded to the substrate using a thin epoxy film. However, glue-bonded PZT mirrors exhibit low reproducibility in measurement results. One source of this variability is water absorption by the substrate\u2019s epoxy adhesive during wet fabrication processes, such as elastic emission machining (EEM), which leads to swelling and deformation. Additionally, longer deformable bimorph mirrors require larger PZT electrodes, further complicating their design and fabrication, particularly during bonding and ultraprecise metrology. To address these challenges, silver nanoparticles were employed to bond PZT elements to the silicon (Si) mirror, eliminating the need for epoxy glue. In this study, we developed an inorganic-glue-free PZT bimorph mirror with a length of 460\u00a0mm and 28 channels. The glue-free bonding method successfully ensured the high reproducibility of measurements after water immersion. This approach resulted in a shape error of only 0.41\u00a0nm root mean square after the figure correction process using an ultraprecise EEM process. Scanning acoustic tomography and basic response function tests confirmed the success of the bonding process, showing no critical voids. Furthermore, the shape changes induced by applying voltages to the PZT electrodes closely matched predictions obtained from simulations. These results demonstrate the reliability and precision of the proposed glue-free bonding technique, paving the way for improved performance of new PZT bimorph mirrors.<\/jats:p>","DOI":"10.1063\/5.0297123","type":"journal-article","created":{"date-parts":[[2026,2,2]],"date-time":"2026-02-02T13:39:38Z","timestamp":1770039578000},"update-policy":"https:\/\/doi.org\/10.1063\/aip-crossmark-policy-page","source":"Crossref","is-referenced-by-count":1,"title":["Development of an ultraprecise glue-free bimorph deformable mirror with a length of 460 mm"],"prefix":"10.1063","volume":"97","author":[{"ORCID":"https:\/\/orcid.org\/0009-0002-7852-3891","authenticated-orcid":false,"given":"Yoshio","family":"Ichii","sequence":"first","affiliation":[{"name":"SLAC National Accelerator Laboratory 1 , 2475 Sand Hill Rd., Menlo Park, California 94025,","place":["USA"]}],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-7159-1296","authenticated-orcid":false,"given":"Takato","family":"Inoue","sequence":"additional","affiliation":[{"name":"Osaka University 2 , 2-1, Yamadaoka, Suita, Osaka 565-0871,","place":["Japan"]},{"name":"Nagoya University 3 , Furo-cho, Chikusa-ku, Nagoya, Aichi 464-8603,","place":["Japan"]}],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-1069-9981","authenticated-orcid":false,"given":"Xianbo","family":"Shi","sequence":"additional","affiliation":[{"name":"Argonne National Laboratory 4 , 9700 S. 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