A -- EFG Sapphire Sheets for Large Aperture EO/IR Windows

NOTICE OF CONTRACT ACTION (NOCA) FOR EFG Sapphire Sheets for Large Aperture EO/IR Windows. The purpose of this NOCA is not to request competitive proposals. The Air Force Research Laboratory, Materials and Manufacturing Directorate, Manufacturing Technology Division (AFRL/MLM) is contemplating the award of a cost-reimbursement type contract to Saint-Gobain Crystals, 33 Powers Street, Milford, NH 03055 for the program entitled "EFG Sapphire Sheets for Large Aperture EO/IR Windows" under the authority of 10 U.S.C. 2304(c)(1) as implemented by FAR 6.302-1, "Only One Responsible Source." The objective of this acquisition shall be to improve the manufacturing processes associated with the production of Edge-defined Film-fed Growth (EFG) sapphire in order to achieve the domestic capability of producing larger window sizes, with increased affordability. This acquisition is being contemplated to enable the production of large (at least 32 inches x 32 inches x 0.8 inch) sapphire sheets. Windows of this size would be extremely useful for multiple airborne and ground-based platforms with large sensor suites which need to be protected from harsh operating conditions over many years of service. Exhibiting broadband transmission from the ultraviolet through the visible and mid-infrared wavelengths, as well as being an extremely hard, durable, scratch-resistant material, sapphire is an excellent candidate for the electro-optical/infrared (EO/IR) window application. However, the use of sapphire windows is currently limited by the size that can be produced and by their cost. Even though sapphire crystals grown by the EFG process are the largest in the world, windows made of EFG sapphire are currently only available with finished sheet sizes up to 9 inches x 26 inches or 12 inches x 20 inches. There are current Air Force activities which would use sapphire windows, if they were available in the required size (at least 32 inches x 32 inches x 0.8 inch). The period of performance for the Phase I procurement is anticipated to be 20 months. The Phase I tasks are to: identify the factors (manufacturing, cost, and technology drivers) limiting the ability to manufacture large (at least 32 inches x 32 inches x 0.8 inch, finished dimensions) monolithic EFG sapphire EO/IR windows; identify the risks associated with the limiting factors; prioritize the factors; formulate a manufacturing plan to mitigate the identified drivers, addressing process optimization and yield improvement to reduce cost; and implement and demonstrate a limited number of manufacturing processes focusing on the critical path, based on available funding. Additional phases to further improve the manufacturing processes associated with producing large EFG sapphire, and to increase the size produced, may be undertaken depending on the progress made and the availability of funding. The ability of the offeror to scale up production and accomplish the related goals of this program will be assessed based on the existing demonstrated ability of the offeror to routinely produce EFG sapphire that exhibits a high degree of optical transparency in the visible through mid-infrared regions of the electromagnetic spectrum, along with very good index-of-refraction homogeneity, in the size range of 12 inches x 20 inches. Transmittance greater than 80 percent, over the wavelength region from 0.4 - 4 microns, is required for quarter-inch-thick samples. Variation in the index of refraction on the order of 6 ppm or less, over the entire window, is also required. It is planned that the initial sole source contract will be awarded for $1,799,821.00 with the potential for future phases that will increase the total estimated amount to $9.8M. Inquiries pertaining to this acquisition should be addressed to Timothy J. Wisecup, Contracting Officer, telephone: (937) 656-9887, facsimile: (937) 255-5302, e-mail: timothy.wisecup@wpafb.af.mil, or Jimmie L. Garrard II, Contract Negotiator, telephone: (937) 656-9744, facsimile: (937) 255-5302, e-mail: jimmie.garrard@wpafb.af.mil at Det 1 AFRL/PKMT, 2310 Eighth Street, Wright Patterson AFB OH 45433-7801. Technical questions may be addressed to Virginia A. McMillan, Project Engineer, AFRL/MLME, telephone: (937) 904-4364, facsimile: (937) 656-4420, e-mail: virginia.mcmillan@wpafb.af.mil. All responsible sources may submit information that shall be considered by the agency. See numbered note 22.