Homeland security systems, special forces, unmanned aerial vehicles (UAV), and marine patrols require low cost, high
performance, multi-mode visible through infrared (VIS-IR) wavelength optical systems to identify and neutralize
potential threats that often arise at long ranges and under poor visibility conditions. Long range and wide spectral
performance requirements favor reflective optical system design solutions. The limited field of view of such designs
can be significantly enhanced by the use of catadioptric optical solutions that utilize molded or diamond point machined
VIS-IR lenses downstream from reflective objective optics. A common optical aperture that services multiple modes of
field-of-view, operating wavelength, and includes laser ranging and spotting, provides the highest utility and is most
ideal for size and weight. Such a design also often requires fast, highly aspheric, reflective, refractive, and sometimes
diffractive surfaces using high performance and aggressively light-weighted materials that demand the finest of
manufacturing technologies. Visible wavelength performance sets the bar for component optical surface irregularity on
the order of 20 nm RMS and surface finishes less than 3.0 nm RMS. Aluminum mirrors and structures can also be
precision machined to yield "snap together alignment" or limited compensation assembly approaches to reduce cost and
enhance interchangeability.
Diamond point turning, die cast and investment cast mirror substrates and structures, computerized optical polishing,
mirror replication, lens molding and other advanced manufacturing technologies can all be used to minimize the cost of
this type of optical equipment. This paper discusses the tradeoffs among materials and process selection for
catadioptric, multi-mode systems that are under development for a variety of DoD and Homeland Security applications.
Several examples are profiled to illuminate the confluence of applicable design and manufacturing technologies.
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