F-35 EOTS Process Improvements Expected to Save $5M

A2883 — F-35 Lightning II Electro-Optical Targeting System (EOTS) Wafer and Focal Plane Array Producibility Improvements

Objective

The EOTS is a high-performance, lightweight, multifunctional system for precise air-to-air and air-to-surface targeting. Production of the EOTS focal plane array sensing element and the integrated dewar-cooler had initially suffered from inefficiencies and were unable to meet production quantities at the required cost points when the EOTS multiple-phase producibility effort was initiated. Since the producibility program’s inception, significant improvements have been made to meet production quantities at the required cost points. Leveraging the success achieved in the previous phases of the F-35 Lightning II EOTS producibility projects, this Electro-Optics Center (EOC) project continues to execute cost and risk reductions for the EOTS infrared detector critical to the production quantity delivery and cost-reduction goals.

Payoff

The current niobium nitride (nBn) wafer fabrication process requires multiple photolithography steps. Implementing process improvements and streamlining the detector wafer fabrication process will eliminate several current manufacturing challenges. Insertion of wafer photolithography process improvements will significantly lower touch labor and cycle time per unit (reduced rework) and improve yield.

The current methods for depositing wafer and focal plane array passivation films are not ideal. Implementing process improvements will reduce or eliminate defects and decrease the number of process steps. Insertion of in-situ etch and passivation process optimizations will improve the yield, performance, and reliability of the focal plane array as well as provide touch time per unit cost savings.

Together, these tasks are expected to save approximately $5M for the F-35 Lightning II Program.

Implementation

The F-35 Lightning II EOTS is the transition platform. These producibility improvements will follow a rolling implementation process – processes will be implemented as they are completed, qualified, approved, and cut into production prior to completion of this project. These manufacturing process-level changes are required to be reviewed and approved by the internal Santa Barbara Focalplane Process Control Review Board. This EOC project will implement multiple industry-approved process changes in FY22 impacting Lots 15 and beyond. This project is also of interest to the Air Force Research Laboratory.