Manufacturing Near-Net-Shape Conformal Electro-optic Sensor Window Blanks from Spinel

Transparent ceramics are currently utilized by the Department of Defense for electro-optical applications including sensor windows. In addition to providing necessary optical performance, transparent ceramics offer the potential for improved ballistic strength and personnel protection. Conformal electro-optic sensor windows are desirable for future air platforms as they maintain the shape of the aircraft and allow for a larger sensor angle of regard. Spinel is an excellent candidate window material as it is both durable and multi-spectral (UV through MWIR). Currently, only flat or nearly flat blanks of transparent spinel are available. To meet the requirements of future platforms and provide greater design freedom to aeronautic and optical designers, large area conformal sensor windows are necessary. The objective of this program is to demonstrate a manufacturing process for near net shape spinel blanks for large conformal sensor windows. CeraNova’s fine grain size transparent spinel presents advantages over other available spinels due to its enhanced strength. CeraNova proposes to further develop and demonstrate a new manufacturing process to provide near net shape transparent ceramic spinel blanks. CeraNova will scale the process to dimensions on the order of 16 inches square with 6 inches of sag.