Optimally Packaged Assembly for Laser Systems (OPALS)

The Air Force requires light weight, compactly packaged optical systems to perform critical beam control functions for airborne high energy laser systems. The purpose of this topic is not to develop new outer moldlines or turret designs for airborne systems but rather focus on optimizing the packaging and performance of the internal optical system required to perform the core beam control functions. A canonical layout of such system is available in Reference 1. The Government expects the designed beam control system will perform all functions laid out in the canonical design - or that any deviations are thoroughly understood and technically justified. Additionally, designs should prioritize ease of alignment and component replacement, potential for line replaceable units, beam path conditioning, and material free of shedding contaminants which could lead to foreign object damage. In order to achieve these objectives, the Government anticipates investigations into the following areas, although this list is informational and is intended to be neither proscriptive nor comprehensive:Ruggedized Optical Design and MaterialsRobust Packaging and Assembly TechniquesNovel Optical Architectures: Explore and develop innovative optical designs inherently tolerant to vibrations, shocks, and thermal gradients.Advanced Materials Selection: Investigate and characterize advanced materials with superior thermo-mechanical properties. This includes exploring specialized glasses, ceramics, and composites for optical elements and mounting structures.Advanced Manufacturing and Assembly Processes: Investigate and implement advanced manufacturing techniques, such as additive manufacturing and precision micro-assembly, to fabricate intricate components and achieve high-precision alignment and bonding of optical elements.Athermalized Design Strategies: Implement passive and active athermalization techniques to mitigate the performance degradation caused by temperature fluctuations. This involves optimizing material choices, employing thermal compensation methods.

Objective

High-energy lasers integrated onto airborne platforms hold immense potential for a variety of applications, relevant to DAF missions. However, the demanding operational environments encountered by airborne systems, characterized by factors like vibration, shock, temperature fluctuations, and pressure variations, pose significant challenges to the performance and reliability of traditional optical systems. To achieve demanding pointing and line of sight stabilization requirements necessary for the laser to have the desired effect on target, a precision optical beam control system is required to sense and correct platform induced disturbances, acquire and track targets, and sense and compensate for atmospheric and aero-optical disturbances. Historically these optical systems are implemented on flat optical benches or breadboards, in a similar manner to a ground-based laboratory. To fully realize the potential of airborne laser systems, there is a critical need for innovative optical systems designed specifically for ruggedness and environmental stability. This research effort aims to develop and demonstrate a ruggedized, environmentally stable, and optimally packaged optical beam control system specifically tailored for airborne high-energy laser applications, in a more optimized form factor for an airborne system than a conventional flat optical bench or breadboard.

Phase I

In phase I the basic concept for the beam control mounting structure will be developed and investigated. Initial performance estimates will be modeled and an initial estimate of size and weight will be calculated. The Government anticipates numerous trade studies and design excursions to create the conceptual design for the OPALS beam control subsystem. During Phase I, concepts developed should be as platform agnostic as feasible. The Government will provide platform representative vibration spectra for performance analysis. The Government anticipates the majority of the concept development to support a Phase II prototype capable of propagating an up to ~20kW laser. However, the concept should also address issues relating to the transition to the phase III operationalized system, capable of accepting a laser of at least 300kW.

Phase II

For the Phase II, the proposals should include development, installation, integration, demonstration, test and evaluation of the proposed optimally packaged beam control prototype system. This Phase II will seek to implement and demonstrate the feasibility of the optimally packaged beam control subsystem using a government furnished laser with power <= 20 kW, for both ground and airborne laboratory tests. AFRL is developing an Airborne Laser System Integration Laboratory to perform experimentation of advanced technologies and concepts relating to airborne high energy laser systems. The first iterations of this laboratory system will have a conventionally implemented (i.e. bench based) beam control subsystem, but subsequent upgrades are planned, and if successful we anticipate demonstrating the OPALS beam control subsystem in this laboratory. AFRL will work collaboratively to define interfaces, develop requirements, and further refine performance estimates. The work done as part of this proposed effort should be applicable to reduce risk for a full-scale system design. Efforts will include:- Perform relevant modeling and simulation to facilitate system design- Design, build, and field test a ground-based demonstration beam control subsystem to collaboratively operate with AFRL laser source- Deliver the system and associated documentation to AFRL

Phase III

Phase III will focus on scaling up the phase II prototype into an beam control subsystem for integration onto a large, operationally relevant aircraft. The developer and AFRL will work directly with a transition partner in order to incorporate the OPALS technology into a high energy laser system significantly more powerful than the prototype system - anticipated to be at least 300kW.

Keywords: beam control, high energy laser, opto-mechanical packaging

Technology areas: Air Platform

Focus areas: Directed Energy (DE)

CMMC level: Level 2 (Self)