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Western Space And Missile Center, Vandenberg AFB, California, USA
SLRSC Western Range Depot Optics Group (WRDOG)
Steven Elieson, BOE, Supervisor
VAFB Optical Test Facility
The following Cost Avoidance Initiative covers a five year period following the introduction of the polymer First Contact, developed by Dr. James Hamilton of the University of Wisconsin-Platteville and manufactured by Photonic Cleaning Technologies, LLC.
Fundamental Assumptions:
Industry rule-of-thumb recommendation is that optical mirrors are to be recoated after 10 years of service.
Currently these coatings are cleaned using a “drag wipe” method which introduces the risk of scratching the coating.
The traditional methodology requires the use of hazardous chemicals such as spectroscopic grade Acetone and Methanol and high grade Isopropanol (isopropyl alcohol).
The current lens cleaning procedure used on both missile test ranges requires both special training and experience with optics.
Financial Impact Estimate Based on a 5-Year Extrapolation:
Western Range has 5 each 24-in aperture telescopes
Cost to recoat is $60,000 x 5 = $300,000 (includes labor cost to dismantle, disassemble, transport, reinstall the mirrors and to re-collimate the telescope) All WR telescopes (except DOAMS) exceed the 10 year service coating useful life. Each of these telescopes could require as much as 70 days to dismount, recoat, transport, remount and re-collimate (system alignment). There would be a significant handling risk in the mirror removal, transportation and recoat and reinstallation process. The recoat vendor accepts no liability for the handling of these optics.
Western Range has 2 each 36-in aperture telescopes
Cost to recoat is $110,000 x 2 = $220,000 (includes labor cost to dismantle, disassemble, transport, reinstall the mirrors and re-align the telescope) Each of these telescopes has exceeded the 10 year useful coating life expectancy. Each of these telescopes would require a minimum of 70 days each to process. In addition, due to the size and weight and location on a remote mountain peak, there exists a very high handing risk in the mirror removal, crating, transportation, recoat, and reinstallation process. The recoat vendor accepts no liability for the handling of these optics.
Western Range has 60 each 12” medium aperture telescopes in active inventory Cost to recoat each optical system is $6,000 x 60 = $360,000 Each telescope is over 20 years old and has never been recoated. Each of these telescopes would require a minimum of 45 days for vendor turn around time (vendor has taken up to a year in some cases). There is a significant handling risk in the removal, transportation and recoat process. The recoat vendor accepts no liability for the handling of these optics. The polymer cleaning method was found to avoid recoating even in some extreme cases and greatly reduced handling risks; also the associated turn-around time and labor costs.
Western Range has 686 Camera Lenses (Nikon, Pentax, Schneider, etc.) in active inventory.
Cost to recoat 20% of the front and rear elements is approximately $300 each x 686 elements = $205,800 Cameras lenses often have 5 or more elements. However, the front and rear elements are most commonly in need of recoat.
Lens cleaning materials cost over 5 years is approximately $30,000 (lint-free tissue, powder-free gloves, spectroscopic grade chemicals, etc).
Total Estimated savings over a five year period = $1,115,800
Subjective Evaluation
Environmental Impact - No hazardous waste is generated. Over 90% of previously used harsh solvents (‘hazardous material source’) has been eliminated.
Customer satisfaction - What has historically taken up to a year to turn around is now being accomplished in less than 30 days. This translates to a higher customer ‘performance approval rating’ and greater award fees. Training – No special optical background, prior experience, training, education, or special skills necessary; eliminates the need for complicated optical cleaning methodologies and stringent, time consuming cleaning procedures. Acceptance testing – provides an excellent method for optical acceptance tests; only very old, damaged (degraded) or poor quality optical coatings are at risk. Eliminates or greatly minimizes most clean room issues – minimizes dust and particulate concerns; radically reduces special handling concerns. Fingerprints are removed easily and the polymer acts as a surface protection coating.
Total Estimated Impact over the life of the SLRSC contract = Priceless
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