Thin Film Coating Performance - Advanced Thin Film Technology
Optical coatings are ultra-thin layers deposited on optics to manage reflection, transmission, polarization, and durability. There is a wide variety of thin film coatings, each designed for diverse applications across industries. Thin film coatings are used in various fields such as electronics, optics, medicine, and research. In EO/IR systems, thin film coatings ensure high transmission and long-life protection for lenses, sensors, mirrors, and windows got.
Thin films play a critical role in both active and passive devices. Our team engineers thin film coatings that meet tight film thickness tolerances while withstanding shock, vibration, humidity, sand, and salt spray. The ability of different materials to form stable thin film coatings is crucial, as it impacts manufacturing efficiency and stability. Thin film coatings are also used to improve the mechanical, optical, and environmental properties of devices.
Examples of thin film coating applications include anti-reflective anti-scratch, and polarization coatings.
We employ multiple coating methods including thin film deposition by chemical vapor deposition, ion-assisted carbon, spin coating, and dip coating. Each coating process is selected based on the target material, the substrate, and the required coating thickness.
Optical Coating Design & Verification
Our in-house team designs our thin film methods and formulas that spans the multispectral environment which includes UV, visible, NIR, SWIR, MWIR, and LWIR with oxides, metals, and select rare-earth materials to tune spectral bands. We model thin film deposition techniques to manage morphology, surface adhesion, mechanical properties (stress, hardness), and layer uniformity while minimizing coating defects. The optical properties of thin films are determined by their refractive index, extinction coefficient, and structural features. Selecting the appropriate deposition technique is essential for achieving desired film properties.
Performance of your coating depends on:
- Processing discipline (cleanliness, fixturing, bakeouts)
- Number of layers and tight film thickness tolerances
- Refractive-index contrast and surface diffusion behavior
- Matching coating material to the substrate (e.g., germanium vs. sapphire)
- Thin film morphology which describes the structural characteristics of thin layers of material, encompassing aspects like surface roughness, internal void networks, and the overall arrangement of grains and columns.
- The requirement for precise temperature and chamber conditions for high-quality coatings.
- The microstructures of thin films, such as grain boundaries and dislocations, are critical to their performance. These microstructures are characterized using advanced microscopy and diffraction techniques.
We validate designs through in-line and post-process deposition process checks, spectral verification, and environmental screening.
Critical Pre- and Post- Coating Steps
Precision Cleaning
We begin with automated ultrasonic lines to deliver a meticulous substrate surface that promotes adhesion and long-term reliability.
Inspection & Standards
Each deposited film is inspected to ANSI, MIL-SPEC, and ISO 10110. This replaces guesswork with standardized acceptance criteria and traceable quality records.
Protective Coatings: DLC & Hard Carbon Coating
Clear Align produces coatings such as diamond-like carbon (DLC) and other hard coatings. These coatings manage thickness to protect windows against abrasion, salt spray, and particle impacts. These advanced coatings provide improved durability and performance for optical surfaces. The advantages of using advanced coatings include enhanced protection and longer service life for critical components.
We also offer anti-reflective coatings to reduce Fresnel loss across the visible range and infrared. These AR coatings are improving the reliability and image quality of optical systems by minimizing unwanted reflections and enhancing light transmission. Ion-assisted thin film deposition processes produce uniform film coatings on flat and curved optics, and our AR portfolio is tailored for ISR payloads, laser systems, and high-NA assemblies.