N102-165 TITLE: Optically Precise Conformal Sensor Window

TECHNOLOGY AREAS: Air Platform, Materials/Processes, Sensors

ACQUISITION PROGRAM: Naval Unmanned Combat Air System PMA-268

RESTRICTION ON PERFORMANCE BY FOREIGN CITIZENS (i.e., those holding non-U.S. Passports): This topic is "ITAR Restricted." The information and materials provided pursuant to or resulting from this topic are restricted under the International Traffic in Arms Regulations (ITAR), 22 CFR Parts 120 - 130, which control the export of defense-related material and services, including the export of sensitive technical data. Foreign Citizens may perform work under an award resulting from this topic only if they hold the "Permanent Resident Card", or are designated as "Protected Individuals" as defined by 8 U.S.C. 1324b(a)(3). If a proposal for this topic contains participation by a foreign citizen who is not in one of the above two categories, the proposal will be rejected.

OBJECTIVE: Produce a durable, conformal midwave-infrared-transmitting window with a shape such as a toroid and lateral dimensions of 30 x 30 cm with surface figure accuracy of 1 micron. The preferred material is spinel, but other materials with at least an equally wide infrared bandpass and similar erosion resistance will be considered.

DESCRIPTION: Future air vehicles will benefit from sensor windows that conform to the shape of the airframe. The goal of this SBIR topic is to advance the state of the art of grinding, polishing, and measuring conformal shapes without rotational symmetry and made of hard materials. Proposals may cover fabrication or metrology or both. A fabrication-centered proposal must identify the available metrology that will be used to assess how well the fabricated part meets dimensional specifications. An example of a possible window shape to be targeted for the end of Phase II would be a 30 x 30 cm toroid with a radius of curvature of 30 cm along one axis and 60 cm along the perpendicular axis.

PHASE I: Demonstrate key aspects of the proposed technology by making or measuring a toroid or other selected shape with lateral dimensions of 10 x 10 cm. For fabrication, either spinel or another hard optical material can be selected in consultation with the Government. Demonstrate that the part can be made with peak-to-valley surface shape accuracy within +/- 1 micron of the theoretical shape.

PHASE II: Scale up to make or measure a spinel toroid or other selected shape with lateral dimensions of 30 x 30 cm. Demonstrate that the part can be made with peak-to-valley surface shape accuracy within +/- 0.2 micron of the theoretical shape over the entire clear aperture.

PHASE III: Implement commercial production of 50 x 50 cm or larger conformal windows suitable for high quality imaging sensors.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: Conformal windows could be used for synthetic vision systems on commercial aircraft. These windows could increase the pilot�s field of regard and might be used in locations that would not be suitable for flat windows.

REFERENCES:
1. G. P. H. Gubbels, B. E. H. Venrooy, and R. Henselmans, "Accuracy of Freeform Manufacturing Processes," Proc. SPIE 2009, 7426, 742607.

2. R. Henselmans, L. Cacace, G. Kramer, N. Rosielle, and M. Steinbuch, "Nanometer Level Freeform Surface Measurements with the NANOMEFOS Non-contact Measurement Machine," Proc. SPIE 2009, 7426, 742606.

3. S. Bambrick, M. Bechtold, S. DeFisher, D. Mohring, and J. Meisenzahl, "Recent Developments in Finishing of Deep Concave, Aspheric, and Plano Surfaces Utilizing the Ultraform 5-Axis Coputer Controlled System," Proc. SPIE 2009, 7302, 73020U.

KEYWORDS: Conformal optics; freeform optics; aspheric optics; optical fabrication; optical metrology; infrared window

** TOPIC AUTHOR (TPOC) **

DoD Notice:   Between April 21 and May 19, 2010, you may talk directly with the Topic Authors to ask technical questions about the topics. For reasons of competitive fairness, direct communication between proposers and topic authors is not allowed starting May 19, 2010, when DoD begins accepting proposals for this solicitation.

However, proposers may still submit written questions about solicitation topics through the DoD's SBIR/STTR Interactive Topic Information System (SITIS), in which the questioner and respondent remain anonymous and all questions and answers are posted electronically for general viewing until the solicitation closes. All proposers are advised to monitor SITIS (10.2 Q&A) during the solicitation period for questions and answers, and other significant information, relevant to the SBIR 10.2 topic under which they are proposing.

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