Development of a Two-color MWIR LED Array Infrared Scene Projector Technology and Integrated Supply Chain

Advancements in mid-wave infrared (MWIR) emitter technology are essential for improving Infrared Scene Projection (IRSP) assets. Developing a large format dual-band MWIR LED array, with high intensity emission in two distinct narrow-bands, would be a step change. Achieving this advance requires two aspects of today’s MWIR LEDs to be significantly improved. Firstly, the limited emission intensity of MWIR LEDs must be increased, to allow simulation of temperatures up to 1500K. Secondly, the broadband emission spectrum typical of MWIR LEDs, must be dramatically reduced to allow for two distinct LED colors. Our solution is to integrate the best available MWIR LED emitter structures within monolithically integrated resonant optical cavities, designed to emit two distinct wavelengths when fabricated into side-by-side pixels. Crucially, the cavities both enhance emission intensity from the resonant cavity enhanced LEDs (RC-LEDs) and define their narrow (?? < 100 nm) emission bands, offering a transformational IRSP technology. Amethyst Research is a leader in developing MWIR RC devices. Based on our world leading experience, we will develop two design architectures for dual-color RC-LED arrays. Our “low-risk” solution evolves a structure demonstrated in single color, single element RC-LEDs, with a single-band distributed Bragg reflector. By adjusting the cavity thicknesses between the DBR and a metal contact mirror, the required dual emission wavelengths can be engineered. To allow for increased freedom in the separation of the two emission colors and even better enhancement of the emission spectrum, we have also developed a “maximum-reward” architecture. This maximizes potential by integrating a novel dual-stopband DBR. The delivery of this technology requires a highly select group of specialized partners to ensure that the RC-LED design can be driven by suitable RIIC and also manufactured. We have united the leading players in the III-V/Si ecosystem: Amethyst Research, leaders in resonant cavity design, Naval Research Laboratory, leaders in RC-LED design, Santa Barbara Infrared, providing their MON005 Universal 2048 x 2048 RIIC, with 24 µm pitch that can drive the RC-LEDs, Attollo Engineering and QMagiQ leaders in Si/III-V hybridization and manufacture, and IntelliEPI, leaders in III-V epi growth. In Phase I, we will deliver a comprehensive report together with full manufacturing protocols on the design of a two-color MWIR RC-LED array that can be hybridized with the MON005 Universal RIIC, providing a 24 µm pitch, 2048 x 2048 array. It will include manufacturing costs and schedule options for RC-LED array delivery in Phase II. It will also detail designs that offer various wavelength options, depending on the Navy’s specific requirements. In Phase II, we will develop the necessary manufacturing partnerships within the supply chain, and demonstrate a two-color MWIR (3–5 µm) narrow spectral band (< 100 nm) LED array with a 300–1500 K dynamic range.