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Freeform Optical Systems for Defense System Optics

Award Information
Agency: Department of Defense
Branch: Missile Defense Agency
Contract: W9113M-09-C-0028
Agency Tracking Number: B074-006-0097
Amount: $750,000.00
Phase: Phase II
Program: STTR
Solicitation Topic Code: MDA07-T006
Solicitation Number: N/A
Solicitation Year: 2007
Award Year: 2009
Award Start Date (Proposal Award Date): 2009-01-06
Award End Date (Contract End Date): 2011-01-06
Small Business Information
7900 West 78th St. Suite 300
Minneapolis, MN 55439
United States
DUNS: 938966090
HUBZone Owned: No
Woman Owned: No
Socially and Economically Disadvantaged: No
Principal Investigator
 Troy Marusich
 Chief Technical Officer
 (952) 832-5515
Business Contact
 Lisa Ferris
Title: Chief Operating Officer
Phone: (952) 832-5515
Research Institution
 Western Michigan University
 John Patten
1903 West Michigan Ave College of Engineering
Kalamazoo, MI 49008
United States

 (269) 276-3246
 Nonprofit college or university

Freeform optical surfaces offer advantages over axisymmetric surfaces in the ability to reduce optical sizes, increase performance and reduce aberrations. However, the description, fabrication and metrology of these surfaces can be difficult and costly, prohibiting their ability to achieve their full potential. Fabrication of these surfaces can be difficult since they are not axisymmetric and have varying local radii of curvature, rendering grinding, lapping and polishing of these surfaces untenable. A method to overcome the difficulties in fabrication of freeform surfaces is to apply ductile mode machining (DMM) to eliminate grinding, lapping and polishing. DMM has been demonstrated on SiC mirror representative of freeform optics in Phase I. Through the use of physics-based modeling, DMM conditions can be identified where material removal results in ductile chip formation, damage free surfaces and excellent surface finish. This STTR activity extends the technology of DMM to freeform configurations enabled by physics-based modeling techniques. We will further develop, enhance and validate the modeling capability and apply it to CVD coated SiC freeform optics. Backed by modeling data, we will perform a set of machining experiments to ascertain the DMM operating envelope and subsequently demonstrate the fabrication of a full scale freeform optic.

* Information listed above is at the time of submission. *

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