High Energy Laser Optically Rugged Maritime Beam Director Components & Subassemblies

The DON26TZ01-NV017 program seeks innovative manufacturing processes for high-energy laser optics and subassemblies for maritime beam directors. The objective is to develop durable, rugged, and reliable components (10cm to 100cm diameter) through automated and additive manufacturing techniques, including finishing processes like coating and polishing. This initiative addresses current challenges of long lead times, high rejection rates, and low ruggedness in existing optics, which impact naval readiness. The Navy prioritizes “on-demand” additive 3D printing and highly automated finishing for cost reduction and rapid production of high-quality optical surfaces, especially for components with limited environmental lifetimes. Phase I focuses on small-scale replication (10-25cm) of optical components for laser-induced damage testing, demonstrating scalability for full-scale beam directors. Phase II scales up to 30-100cm components, integrating mechanical and electronic controls for a full-scale beam director, with an objective to rapidly replace components within one month. Phase III involves transitioning these components into Navy high-energy laser weapons systems and exploring commercial applications such as LADAR systems and missile defense initiatives. The project requires U.S. owned and operated contractors with secret level facility and personnel security clearances.