OSW27TZ02-NV001 — Wafer-scale low-loss hyperbolic optical material

The overall goal of the R&D effort is to develop wafer-scale, fabrication-ready thin films of a low-loss naturally hyperbolic optical material that operates across the visible to telecommunication wavelength range. Films should be of high optical and crystalline quality, with controlled thickness and orientation, on substrates at least one inch in cross-sectional diameter.

Conventional optical systems are limited by diffraction, which sets the smallest features they can pattern, image, or confine to roughly the wavelength of the light used. A class of strongly anisotropic, or "hyperbolic," optical materials can confine and route light far below this limit, enabling a family of compact, low size-weight-and-power photonic components of direct interest to OUSW (R&E). Hyperbolic behavior has historically been realized in artificial metamaterials, which are optically lossy, and difficult to fabricate and scale. Certain naturally occurring crystals exhibit the same behavior with far lower loss, but the available examples operate only in the infrared and have been produced only as small, research-grade crystals by batch methods incompatible with standard microfabrication. There is presently no commercial source of wafer-scale, low-loss hyperbolic material that operates at visible and telecommunication wavelengths in a form compatible with standard semiconductor fabrication, and it is important for the Air Force to establish a domestic supply source for such a material.

Establish the feasibility of producing the hyperbolic material as wafer-scale, device-grade thin films with the required optical quality and crystalline orientation across the target wavelength range. Characterize and/or predict the optical performance of the films and benchmark it against existing artificial metamaterial approaches. Identify a viable approach for lithographically patterning and integrating the material. As a Small Business Technology Transfer (STTR) effort, the work must be performed in partnership with a research institution; a partner with established expertise in optical measurement of hyperbolic materials is encouraged. Deliverables include a feasibility assessment with supporting analysis and/or preliminary data, quantitative performance projections, and a detailed Phase II plan. Documentation may comprise technical reports, peer-reviewed publications, measured data, and design artifacts sufficient to substantiate the scientific, technical, and commercial merit required to enter Phase II.

Deliver wafer-scale films/wafers (at least one inch in cross-section, with a demonstrated path to larger wafers) of the low-loss hyperbolic material, with controlled thickness, orientation, and uniformity, reproducibly and with reasonable yield. Demonstrate lithographic patterning and integration of the material. Provide quantitative performance data benchmarked against incumbent approaches, together with a manufacturing-readiness and transition plan.

The awardee will pursue commercialization of the technologies developed in Phase II, transitioning expanded capability to government and civilian users to microelectronics fabrication and inspection, compact optics and photonics, and/or quantum light sources. Direct access to end-users and government customers will be provided, with opportunities for Phase III awards for additional research and development or direct procurement of the products and services developed in coordination with the program. Phase III efforts are intended to transition technologies developed with further scaling of performance metrics for dual use applications into operational use and/or commercial markets, leveraging non-SBIR/STTR funding. Phase III work may include productization, integration, certification, and large-scale deployment of the capability developed in Phases I and II. By effectively executing Phase III effort and transitioning the technology into operational and commercial use, the project aims to maximize the impact and value of the STTR-funded R&D efforts, ultimately contributing to national security, economic growth, and technological innovation. A design for performance approach for defense system in partnership with a defense contractor and a design for cost for commercial applications will be planned.