Thin Solid Films, Vol.515, No.3, 854-858, 2006
Fabrication of optical elements with better than lambda/1000 thickness uniformity by thin-film deposition through a multi-aperture mask
A technique is presented for sub-nanometre correction of precision-polished optical surfaces. The technique uses thin metallic masks with multiple apertures of varying widths to selectively occlude a beam of depositing species in an ion beam sputtering system. The masks are designed directly from measured surface profile maps of the optical surface, and are fabricated using well-established laser-cutting technology commonly used to fabricate solder masks for the semiconductor industry. The selective deposition has proved highly effective for fabrication of large-aperture Fabry-Perot filters and has resulted in optical uniformities of less then 0.3 nm rms over a clear aperture of 37.5 mm. This manuscript will give details of the mask design, deposition technique, and results from recent surface correction runs. (c) 2006 Elsevier B.V. All rights reserved.
Keywords:deposition process;optical coatings;physical vapour deposition (PVD);optical surface correction