Improved Method for Optical Fabrication of Conformal ALON Sensor Windows

Current fabrication processes for ceramic conformal window optics are high-cost and fairly inefficient. Surmet is a vertically integrated manufacturer of durable visible-MWIR ALON® and Spinel precision optics. Through this program, we will develop and demonstrate innovative technology conformal window for fabrication; showing a major improvement in time, cost, and quality. Surmet has already proven technical feasibility of all innovative aspects of the proposed technology. Surmet has the necessary resources and expertise to refine and scale-up the technology. This technology is applicable to all window material candidates. The Phase II program will optimize processes in three stages, culminating in conformal window shape, size and specifications stated in the SBIR topic description. Phase II work will involve manufacture and evaluation of a substantial number of parts as needed to demonstrate reliability and repeatability of processes. Results will be used to assess and document producibility, performance and production cost; and also to update TRL analysis throughout the Phase II. Phase II will also include key hardware Deliverables at each stage, to MDA. Surmet has assembled a strong team that consists of renown technical experts and Defense Prime Contractor commercialization partners. Through their valuable support, the Phase II program will develop the technology to TRL 6, and ready for commercialization. As a current manufacturer and supplier of ALON/Spinel optics and blanks, Surmet is in an excellent position to commercialize the proposed technology. Surmet has an excellent SBIR commercialization track record, and a strong strategy to commercialize Phase II technology in MDA, other DOD, and industrial systems. Approved for Public Release | 23-MDA-11401 (14 Mar 23)