Optical Coatings for Deep Concave Surface

The objective of this SBIR topic is to develop methods to apply robust, high operating temperature anti-reflective coatings, over the wavelength range 3 to 5 microns, to the inside of deep concave surfaces, including a tangent ogive infrared dome. In Phase 1 we will develop methods which control the coating thickness across the interior surface of the dome such that the coating performance is optimized over a wide range of look angles for an IR seeker positioned inside the dome itself. We propose to solve the thickness control challenges by using shadow masking techniques to control uniformity, coupled with 3 dimensional mathematical modeling to predict deterministically the shape of the shadow mask. This approach will save considerable time and expense. We will use Ion Beam Sputtering (IBS) technology to deposit the Anti-Reflective coating on the interior of the dome, (in Phase 1 option and in Phase 2), thereby gaining the benefits of the high energy IBS deposition process. Those benefits include: Amorphous film structure, near bulk density, improved film adhesion, automated deposition process, and environmental stability.