Production of Non-Traditional Optical Surfaces for Surveillance, Target Acquisition and Guidance

While fulfilling the direct function as a part of imaging and sensors system, optics for future airborne weapons must conform to the aerodynamic shape of the missile or aircraft body. Replacing the historically hemispheric domes on missiles with more aerodynamic shapes results in benefits such as reduced drag, greater speeds, shorter time to target, longer range and overall greater lethality. Conventional polishing processes used to manufacture flat and spherical optics cannot be utilized for the production of conformal optics such as ogive domes. Some processes, such as MRF, exist that are capable of finishing the outside of an ogive dome, but the concave side still presents a challenge. The feasibility of using MR Jet for precision finishing this class of optics was clearly demonstrated during Phase I, with the precision polishing of a steep concave sphere embedded into an ogive-shaped cavity. During Phase II, the process will be developed further to allow for the cost effective manufacture of truly conformal shapes including cavities with large sag. In addition, a collaborative manufacturing approach will be taken so that the ability to manufacture existing and future domes and windows for government and commercial applications with MR Jet will be clearly demonstrated.