The Department of Defense, specifically the United States Air Force, is seeking proposals for the Small Business Innovation Research (SBIR) program focused on developing a Binary Infrared Modulator Array based on dynamic metamaterials. The objective is to create a high-speed pixel array that operates in binary mode within the mid-infrared spectral region, enhancing the fidelity of scene projection for various sensor systems. This technology is crucial for applications in military projection, communications, and commercial sectors such as autonomous navigation and machine vision. Proposals are due by May 21, 2025, with the opportunity open for submissions starting April 2, 2025. For more details, interested parties can visit the official solicitation page at [SBIR.gov](https://www.sbir.gov/topics/11890).

TECHNOLOGY AREAS: Trusted AI and Autonomy OBJECTIVE: Develop a concept and demonstrate a high-speed pixel array operating in binary mode in the mid infrared spectral region. DESCRIPTION: Mid-wave infrared scene projection is used for testing a variety of sensors and sensor systems [1], and as the complexity of sensor systems increases, the fidelity of scene projection must also increase. Traditional approaches to scene projection hardware include micro resistor arrays [2], infrared LED arrays [3], liquid crystal on silicon (LCOS) modulators [4] and digital micromirror (DMD) devices [5]. All of these suffer from a variety of limitations, but many still provide potential utility as enabling devices. In order to enhance the capacity for high fidelity scene projection, a pixel-wise modulator is desired, operating in a binary format (each pixel can be independently set to 0 or 1) with preference given to designs that operate at room temperature (not cryo-cooled, though thermo-electrically-cooled is acceptable). An on-state (1) pixel will be defined as having the maximum “transmission” of the system and maximum throughput (reflection or transmission) is desired. The off-state (0) of a pixel is defined as having minimum throughput, including secondary emission from local heating, leakage modes, scattering, pixel crosstalk or other mechanisms that contribute to the pixel’s apparent temperature when viewed from the projector output. Off-state is desired to be at least 1000 times lower (-30 dB) than the on-state in terms of pixel “transmittance”. Ultimately, an array is desired that operates in the 3-5 microns midwave infrared region (preference is for designs which are broadband), meets or exceeds a 1000x1000 format with square pixels having pitch between 24μm and 50μm (design scalable to 24μm). The binary scene projector is preferred to operate identically for all polarizations and must not be dependent on the illumination type, only wavelength. Each device in the array should provide maximum extinction of transmitted light when in the “off” mode, must operate above 50 KHz modulation frequency (with a path to increase frequency to 100KHz), have low electrical power consumption, be scalable in manufacturing and have a format that allows for “tiling” of devices. Variations are acceptable for demonstration purposes. The primary extinction mechanism must utilize properties of metamaterials, photonic crystals or plasmonics, though a secondary mechanism is permitted, such as piezo actuation for surface plasmon polaritons or laser addressing for metamaterial phase changes. Self-emitting pixels (LEDs, micro lasers, resistors, etc.) are not acceptable solutions for this topic unless being used for actuation as noted. Metamaterials and photonic crystals are defined here as engineered, non-bulk optical materials. PHASE I: At a minimum for Phase 1, initial designs will be developed and thoroughly evaluated through modeling and simulations, though preference will be given to actual hardware feasibility demonstration. Concept performance will be evaluated based on pixel pitch and format, spectral width of operation, maximum operating frequency, extinction a pixel can provide, repeatability of operation (no gray level operation). Consideration is also provided for manufacturability, design/manufacturing/operation complexity, ability to scale to larger devices and tunability to reach other bands as desired. PHASE II: Refinement of a concept, design, fabrication/demonstration of a prototype and prototype testing will constitute the majority of the Phase 2 effort. All testing is expected to be performed at the firm’s site, with the firm’s equipment (no Government supplied equipment). Any remaining concept refinements needed after a Phase 1 completion will be addressed early in the Phase 2 effort, ideally in parallel with the design efforts. Prototype to be developed should not be specific to a single illumination mechanism (i.e. laser, LED, halogen). The design process should include planning for demonstration and testing/measurements. Fabrication and demonstration of a prototype is expected to require a substantial portion of the phase 2 program due to component purchase lead times and several iterations of fabrication to refine the process. With proper planning for demonstration and testing, the final portion of the phase 2 program should be relatively short and produce high quality data that indicates the designed items function as intended. High performance infrared binary modulator arrays meeting the phase 2 requirements would have immediate commercialization potential with a variety of commercial/industrial applications including structured illumination devices for edge sensing/processing systems, structured illumination for autonomous navigation and machine vision applications (parts/food inspection, sorting, etc.), 3D printing applications. Military uses of binary infrared modulator arrays include projection applications and communications. PHASE III DUAL USE APPLICATIONS: Outputs from Phase 2 are anticipated to be TRL 7 but may require additional effort to refine to a more manufacturable design. Phase 3 will concentrate on the manufacturability as well as the fabrication process itself to prepare the vendor to commercially offer a fully functional product. A final product is expected to be demonstrated and marketed to AFRL and transition partner in the 782d Test Squadron. Additional Phase 3 planning will occur during the Phase 2 process once a design is established and manufacturing requirements and manufacturability become more apparent. REFERENCES: 1. Williams, O.M. (1998). Dynamic infrared scene projection: a review. Infrared Physics & Technology, 39, 473-486. 2. Steve McHugh, Greg Franks, and Joe LaVeigne "High-temperature MIRAGE XL (LFRA) IRSP system development", Proc. SPIE 10178, Infrared Imaging Systems: Design, Analysis, Modeling, and Testing XXVIII, 1017809 (3 May 2017). 3. G. A. Ejzak et al., "512 × 512, 100 Hz Mid-Wave Infrared LED Microdisplay System," in Journal of Display Technology, vol. 12, no. 10, pp. 1139-1144, Oct. 2016. 4. Anna Linnenberger, Hugh Masterson, Joseph P. Rice, and Jay Stockley "Liquid-crystal-based hyperspectral image projector", Proc. SPIE 7695, Algorithms and Technologies for Multispectral, Hyperspectral, and Ultraspectral Imagery XVI, 76951Z (12 May 2010). 5. Stirling Scholes, Ravin Kara, Jonathan Pinnell, Valeria Rodríguez-Fajardo, and Andrew Forbes "Structured light with digital micromirror devices: a guide to best practice," Optical Engineering 59(4), 041202 (21 November 2019). KEYWORDS: Scene Projection; Spatial Light Modulator; Infrared Scene Generation; Binary Modulator; High Frequency; Metamaterials; Plasmonics; Hardware in the Loop Testing

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