Manufacturing Issues for Multimode Seeker Domes

There are currently three different approaches under consideration for construction of multi-layer hemispherical multi-mode domes: (1) The bonded shell method – in which an inner and an outer dome shell are fabricated out of either ALON or Spinel, and subsequently bonded together, using a transparent adhesive, with a metallic grid at the interface to create the desired structure.; (2) The alternate dielectric method- in which an outer shell is fabricated out of either ALON or spinel, a grid is applied to its inner surface, and then an alternate dielectric material is directly bonded to it to create the desired structure; and (3) The Co-fired ceramic method- in which the metal grid is applied to green ceramics, and then fired to create the multi-layer structure within the as fired blank. This Phase I will analyze the processes used in each of these approaches, and select the method most likely to produce a cost effective multi-layer dome in quantities up to 250/month. At the conclusion, any remaining process steps not mature will have a cost/risk reduction analysis presented. The Phase II effort would then consist of optimizing the selected method and demonstrating the feasibility of producing these domes in large quantities.