Infrared Coating Process Improvements for Detectors

OUSD (R&E) MODERNIZATION PRIORITY: Directed Energy; General Warfighting Requirements (GWR) TECHNOLOGY AREA(S): Sensors; Materials The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), 22 CFR Parts 120-130, which controls the export and import of defense-related material and services, including export of sensitive technical data, or the Export Administration Regulation (EAR), 15 CFR Parts 730-774, which controls dual use items. Offerors must disclose any proposed use of foreign nationals (FNs), their country(ies) of origin, the type of visa or work permit possessed, and the statement of work (SOW) tasks intended for accomplishment by the FN(s) in accordance with the Announcement. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws. Please direct questions to the Air Force SBIR/STTR HelpDesk: usaf.team@afsbirsttr.us. OBJECTIVE: Program objective is manufacturing processes improvement for high performance thin film coatings for infrared (> 2 m) electro-optical imaging applications. These multi-layer coatings require tight manufacturing tolerances in order to meet current and future infrared detector performance specifications. The focus would be on improving the uniformity of the infrared coatings to meet the requirements for both spectral (e.g. pass-band transmission or blocking band rejection) and imaging (e.g. scatter, point defects within the coating, scratch/dig specifications on outer layer) performance for DoD applications. DESCRIPTION: A variety of thin film materials are used in multi-layer infrared optical coatings. One of the most challenging thin film coatings to deposit is Germanium. This material can be a large yield detractor when it comes to the building of optical elements for infrared detectors. This program would investigate different deposition processes for Germanium, as well as other candidate materials, on infrared optical materials to improve the overall yield. The government envisions a design of experiments (DOE) type of approach with 2-3 different deposition techniques. Some of the DOE parameters would investigate deposition rate, coating thickness, as well as process induced stress. The different deposition techniques would also take into account the compatibility with other infrared thin film coating materials. There is also interest in metrology development for evaluating the as-deposited thin film coatings on individual optical elements prior to integration and assembly. A secondary focus would be an investigation of different metrology methods to verify coating (spectral and optical quality) performance prior to inserting it into an optical assembly. PHASE I: This topic is intended for technology proven ready to move directly into a Phase II. Therefore, a Phase I award is not required. Phase 1 like proposals will not be evaluated and will be rejected as nonresponsive. The offeror is required to provide detail and documentation in the Direct to Phase II proposal which demonstrates accomplishment of a Phase I-like effort, including a feasibility study. This includes determining, insofar as possible, the scientific and technical merit and feasibility of ideas appearing to have commercial potential. It must have validated the product-market fit between the proposed solution and a potential AF stakeholder. The offeror should have defined a clear, immediately actionable plan with the proposed solution and the AF customer. The feasibility study should have; -Identified the prime potential AF end user(s) for the non-Defense commercial offering to solve the AF need, i.e., how it has been modified; -Described integration cost and feasibility with current mission-specific products; -Described if/how the demonstration can be used by other DoD or Governmental customers. PHASE II: Eligibility for D2P2 is predicated on the offeror having performed a Phase I-like effort predominantly separate from the SBIR Programs. Under the phase II effort, the offeror shall sufficiently develop the technical approach, product, or process in order to conduct a small number of advanced manufacturing and/or sustainment relevant demonstrations. Identification of manufacturing/production issues and or business model modifications required to further improve product or process relevance to improved sustainment costs, availability, or safety, should be documented. Air Force sustainment stakeholder engagement is paramount to successful validation of the technical approach. These Phase II awards are intended to provide a path to commercialization, not the final step for the proposed solution. PHASE III DUAL USE APPLICATIONS: The contractor will pursue commercialization of the various technologies developed in Phase II for transitioning expanded mission capability to a broad range of potential government and civilian users and alternate mission applications. Direct access with end users and government customers will be provided with opportunities to receive Phase III awards for providing the government additional research & development, or direct procurement of products and services developed in coordination with the program. REFERENCES: https://link.springer.com/article/10.1007%2Fs10854-007-9562-4 KEYWORDS: infrared; optics; optical materials; optical coatings; manufacturing processes