Technology Spotlight: Durable Dual-Band Optical Coatings 

Optics are the backbone of next-generation multi-band sensor systems, enabling long-range scout sensors to operate effectively in degraded visual environments. However, the complexity of dual-band coatings, requiring three times the number of layers compared to earlier systems, has historically led to low manufacturing yields, high costs, and reduced durability. 

To address these challenges, the Army ManTech program partnered with DEVCOM C5ISR Center’s Research and Technology Integration (RTI) Directorate, PEO IEW&S, and multiple industry leaders., Together, they tackled the full spectrum of coating development, from chamber preparation and surface conditioning to in-process monitoring and durability testing. 

Innovation in Action 

The integrated team developed a robust coating deposition process that dramatically improved manufacturing yields from below 60% to over 90% across all substrates used in current optical systems. By refining design tolerances, enhancing monitoring techniques, and improving chamber cleanliness, the team achieved: 

• 33% reduction in coating cost per component 
• Mean Time Between Failure (MTBF) increased from <20k hours to >50k hours 
• Return on Investment (ROI) of over 17:1 from a $5M Army ManTech investment 

These improvements not only reduce procurement costs but also drive down long-term maintenance and replacement expenses, delivering enduring value to the Army and broader DOW sensor programs. 

Strategic Impact

This breakthrough directly supports the deployment of advanced dual-band thermal imagers, which provide overmatch capabilities against near-peer adversaries. By improving optical throughput and system range, these coatings enhance mission effectiveness in smoke, fog, and other visually degraded environments. 

Moreover, the success of this initiative sets a precedent for future innovation. As coating complexity increases with emerging sensor platforms, the processes and lessons learned from this ManTech effort will enable more efficient, cost-effective production across the defense industrial base. 

Army FUZE is proud to spotlight this achievement as a model of how coordinated innovation, driven by strategic investment and cross-sector collaboration, can deliver real-world impact for the warfighter.