Exotic Electro-Optics recently conducted a basic evaluation of state-of-the-art spinel material from the standpoint of
optical fabrication. The goal of this study was to characterize the behavior of several spinel samples as they passed
through a complete optical fabrication sequence. Overall, the material was found to be compatible with conventional
fabrication processes. Methodologies used in the manufacture of heritage optical components were employed
successfully, without significant modification, in the fabrication of the spinel windows. A standard anti-reflective
coating was used to coat polished spinel samples. Good coating-to-substrate adhesion was observed and the coated optic
exhibited the expected spectral performance. In this paper, Exotic Electro-Optics reports on the results of this work.
Advances in optical manufacturing and testing technologies for sapphire material are required to support the increasing use of large-aperture sapphire panels as windscreens for various electro-optical system applications. Single surface grinding is a crucial process step in both the figuring and finishing of optical components. Improper grinding can make subsequent polishing operations more difficult and time consuming. Poor grinding can also lead to the introduction of surface stress and sub-surface damage which can affect critical opto-mechanical performance characteristics such as strength and durability. Initial efforts have been completed at Exotic Electro-Optics under the funding of the Office of Naval Research and the Air Force Research Laboratory to investigate a number of process enhancements in the grinding of a-plane sapphire panels. The information gained from this study will ultimately provide a better understanding of the overall manufacturing process leading to optimized process time and cost. EEO has completed two sets of twelve-run Plackett-Burman designs of experiment (DOE) to study the effects of fundamental grinding parameters on sapphire panel surfaces. The relative importance of specific process parameters on window characteristics including surface roughness, stress, sub-surface damage are reported.
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