Manufacturing of Visibly Transparent Large Conformal Windows Navy SBIR FY2015.2 Sol No.: Navy SBIR FY2015.2 Topic No.: N152-107 Topic Title: Manufacturing of Visibly Transparent Large Conformal Windows Proposal No.: N152-107-0566 Firm: OptiPro Systems LLC 6368 Dean Parkway Ontario, New York 14519 Contact: Ed Fess Phone: (585) 265-0160 Abstract: The challenging material requirements, large sizes, and complex geometries for current and future advanced military optical systems are creating numerous manufacturing challenges. These include the methods to fixture the components, advancements in grinding and polishing machines, processing techniques, and methods for measuring them to their demanding optical tolerances. Our goal in this Phase I effort would be to develop a manufacturing process to produce visibly transparent large conformal windows and corrector optical elements. We will build upon our past grinding and polishing knowledge while researching opportunities for improvements, including expansion of our current machine platforms so that we may in a Phase II effort, if awarded, demonstrate the capability to produce conformal shapes up to 24 inches in size. This development effort will focus on further enhancements of OptiPro�s ultrasonic grinding technology (OptiSonic), UltraForm Finishing (UFF), and UltraSmooth Finishing (USF). We will utilize OptiPro�s SXL500 and Triumph XL grinding and polishing platforms to perform this work. We plan to push the limits of the machine�s working envelope to evaluate the likelihood of their use to complete the phase II requirements. Our final goal would be to develop a complete, cost effective, robust manufacturing solution in Phase II. Benefits: OptiPro, as a founding member of the Center for Freeform Optics (CeFO), has gained important knowledge as to the commercial, military, industrial, and Government needs for freeform and conformal optics. The Center for Freeform Optics (CeFO), a National Science Foundation (NSF) �Science and Technology Center�, is an Industry/University Research Center consisting of the University of North Carolina Charlotte, the University of Rochester, Government agencies, and industrial partners. Together, all invested parties are teaming up to push the technology research and developments for these new complex optical systems. Being part of this organization since its inception in 2012 has allowed us to closely observe and understand emerging optical system component requirements for many commercial, industrial, and military applications. Efficient, high precision grinding and polishing, and improved measurement solutions for these large conformal windows are important technological hurdles. The solutions developed in this effort if awarded would help us to develop enhanced manufacturing solutions to reduce manufacturing costs and improve component quality for these special windows and many other military, space exploration, renewable energy, homeland security, industrial, and commercial optical systems. OptiPro has recently been approached for future development of manufacturing solutions for transparent armor which will also benefit greatly from a successful effort in this proposed SBIR. Return