Reduced-Cost Grinding and Polishing of Large Sapphire Windows Navy SBIR FY2011.2 Sol No.: Navy SBIR FY2011.2 Topic No.: N112-105 Topic Title: Reduced-Cost Grinding and Polishing of Large Sapphire Windows Proposal No.: N112-105-0930 Firm: OptiPro Systems LLC 6368 Dean Parkway Ontario, New York 14519 Contact: Edward Fess Phone: (585) 265-0160 Web Site: www.OptiPro.com Abstract: Developing faster more efficient processing methods for the fabrication of large sapphire windows has the potential to reduce their overall cost. The hardness of the material as well as its crystallographic orientation results in low material removal rates that lead to processing times longer than desired. These low removal rates are present in both the grinding and polishing phases of the process and are one of the primary cost drivers. By increasing the material removal rate during fabrication without distorting the optical wavefront, substantial cost savings can be achieved. OptiPro Systems has the unique opportunity to develop a deterministic large aperture polishing (DLAP) process. This process will have the ability to remove material at a rapid rate, and use metrology data as input for controlling the wavefront of the sapphire window. OptiPro's technologically advanced optical manufacturing capabilities along with a support partnership with Ted Turnquist from Meller Optics, an expert in sapphire processing, gives us a very strong team, and a clear path towards solving the difficult problems associated with reducing the grinding and finishing costs associated with manufacturing sapphire windows. Benefits: The anticipated benefits are numerous for reducing the manufacturing costs associated with producing large sapphire windows. Once proven, DLAP can be used for other hard to manufacture materials, such as polycrystalline alumina, ALON or spinel. It is also envisioned that this process will be easily adaptable for spherical shapes. This adaptation would have a significant impact into the manufacturing cost of hemi-spherical missile domes such as JAGM. Return