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Custom Multi-Band Sapphire EO/IR Protective Window | UV-LWIR Optical Window for Aerospace

Custom Multi-Band Sapphire EO/IR Protective Window | UV-LWIR Optical Window for Aerospace
Custom Multi-Band Sapphire EO/IR Protective Window | UV-LWIR Optical Window for AerospaceCustom Multi-Band Sapphire EO/IR Protective Window | UV-LWIR Optical Window for AerospaceCustom Multi-Band Sapphire EO/IR Protective Window | UV-LWIR Optical Window for AerospaceCustom Multi-Band Sapphire EO/IR Protective Window | UV-LWIR Optical Window for AerospaceCustom Multi-Band Sapphire EO/IR Protective Window | UV-LWIR Optical Window for AerospaceCustom Multi-Band Sapphire EO/IR Protective Window | UV-LWIR Optical Window for Aerospace
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CategoriesSapphire Optical Windows
BrandFELIX GLASS optical glass Manufacturing base
ModelFG-EOIR-SAP-WIN-001
MaterialSingle Crystal Sapphire (Al₂O₃)
Spectrum TransmissionUV to IR Multi-Band
HardnessMohs 9
Thermal PropertyExcellent Thermal Shock Resistance
Surface GradeGrade 00 Optical Polish
CoatingCustom Multi-Band AR Coating
MachiningCNC Shaping, Edge Chamfering, Sealing Profiles
ApplicationAerospace EO/IR, Thermal Imaging & Night Vision System
Operating Temp-60℃ ~ +5000℃
Supply ModePrototype Sampling & Mass OEM Production
FOB portSHENGZHEN SHANGHAI GUANGZHOU
Terms of PaymentL/C, D/A, D/P, Western Union, T/T
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Detail Information

Custom Size
1PC Prototype
CNC Machining
Multi-Band AR Coating
Mohs 9 Hardness
OEM/ODM

Custom Sapphire EO/IR Protective Window Manufacturer
Multi-Band UV–LWIR Single Crystal Sapphire Optical Window

Custom single-crystal sapphire EO/IR protective windows engineered to your drawing, crystal orientation and spectral transmission requirements. Precision CNC machining, multi-layer AR coating and military-grade inspection for airborne sensor pods, UAV thermal payloads and ground surveillance systems.

  • 1-Piece Low MOQ Prototype Support
  • Free Engineering Review Before Production
  • C-Plane / A-Plane / R-Plane Crystal Orientation
  • Multi-Band Transmission: UV–Visible–MWIR–LWIR
  • Mohs 9 Surface Hardness, Sand & Rain Erosion Resistant
  • Custom BBAR / Dual-Band / DLC Hard Carbon Coating
  • Full-Scale OEM / ODM Mass Production
Engineering Commitment: Send your drawing, dimensions, crystal orientation or spectral band requirements. Our optical engineers will review your project and recommend a suitable sapphire substrate & coating configuration for free.
Ask Our Engineers Get My Custom Quote
Custom multi-band sapphire EO/IR protective optical window for aerospace thermal imaging

Is Your Current Optical Window Supplier Causing These Problems?

Pain Points With Other Suppliers Felix Glass Solution
Conventional glass only transmits one spectral band, requiring multiple windows for multi-sensor suites Single-crystal sapphire delivers simultaneous transmission from UV through MWIR and into LWIR, allowing one protective window to serve visible, SWIR and thermal sensors behind a single aperture — reducing system complexity and parallax error.
Low-hardness glass scratches easily from sand, rain and particle impact at airspeed Sapphire delivers Mohs 9 surface hardness — second only to diamond among optical materials — providing inherent resistance to sand erosion, rain impact and particulate strike without the weight penalty of thicker glass. Optional DLC hard carbon overcoat available for extreme environments.
Optical glass fractures under rapid thermal cycling from high-altitude cold to low-altitude humidity Sapphire combines high thermal conductivity (~40 W/m·K) with moderate CTE to dissipate thermal gradients rapidly. Our windows survive -60°C to +200°C transitions within 30 seconds without surface degradation or coating delamination.
High reflection loss from uncoated sapphire (n ≈ 1.76, ~14% per surface) We apply custom-designed multi-layer dielectric AR coatings — BBAR, dual-band or multi-layer stacks — using electron-beam evaporation or ion-assisted deposition, reducing average reflectance below 1.5% per surface across the design band.
Wrong crystal orientation causes birefringence and polarization distortion in precision sensors Our engineers select C-plane (0001), A-plane (11-20) or R-plane (1-102) orientation based on your sensor's polarization state and thermal management architecture. C-plane minimizes in-plane birefringence for polarization-sensitive systems.
Supplier requires high MOQ, blocking aerospace prototype and qualification programs We support 1-piece prototype testing for sapphire EO/IR windows, allowing you to verify optical performance, coating durability and assembly fit before committing to qualification or production volumes.
Difficult to find one supplier for precision sapphire machining + multi-layer coating + military-standard inspection Dongguan Felix Glass Co., Ltd. provides integrated control across crystal orientation selection, CNC machining, precision polishing, multi-layer AR coating and full inspection per MIL-PRF-13830B and MIL-C-48497A standards.
Send Your Drawing for Solution

Why Global Aerospace & Defense Buyers Work With Felix Glass

19+ Years

Optical Glass Processing Experience

Mohs 9

Sapphire Surface Hardness

1 Piece

Prototype Support

2–3 Weeks*

Typical Prototype Lead Time

4–6 Weeks*

Typical Production Lead Time

75,000 m²*

Manufacturing Facility

*Actual lead time and production capability depend on crystal orientation, geometry, coating complexity, quantity and project requirements.

One Supplier From Prototype to Qualification to Mass Production. Avoid quality disputes and delivery delays caused by multi-supplier coordination between crystal growers, machining shops and coating houses. We provide integrated control across sapphire boule slicing, CNC machining, precision polishing, multi-layer AR coating and military-standard inspection for your EO/IR protective window projects.

Get One-Stop Sapphire Window Solution

Sapphire Window Engineered for Your EO/IR Application

Multi-band UV-IR sapphire optical window transmission performance

Multi-Band Optical Transmission

Single-crystal sapphire offers usable transmission from ~0.15 μm (UV) through 5.5 μm (MWIR), with extended LWIR performance depending on thickness and coating.

  • UV (0.25–0.38 μm): ≥80% uncoated
  • Visible (0.38–0.78 μm): ≥86% uncoated
  • SWIR (0.9–1.7 μm): ≥85% uncoated
  • MWIR (3.0–5.0 μm): ≥82% with BBAR
  • LWIR (8.0–12.0 μm): ≥70% thin substrate

Recommended Solution: C-Plane Sapphire + Custom Multi-Layer BBAR Coating + Precision Polishing

Discuss Your Spectral Requirement →
Single crystal sapphire material properties surface hardness thermal shock

Material & Mechanical Performance

Sapphire (Al₂O₃) delivers four properties no other optical material combines simultaneously: extreme hardness, high thermal conductivity, high melting point and chemical inertness.

  • Mohs 9 Hardness (Knoop 2,000 kg/mm²)
  • Thermal Conductivity ~40 W/m·K @300K
  • Melting Point 2,050°C
  • Young's Modulus 435 GPa (C-plane)
  • Density 3.98 g/cm³
  • Thermal Shock ΔT ≥200°C survivable

Recommended Solution: A-Plane Sapphire for High Thermal Conductivity + DLC Hard Carbon Overcoat

Request Material Data Sheet →
Sapphire EO/IR window aerospace applications airborne turret UAV payload

Coating Technology & AR Design

Custom multi-layer dielectric coatings applied via electron-beam evaporation or ion-assisted deposition, optimized for your specific sensor wavelength bands.

  • Broadband AR (BBAR): ≤1.5% reflectance/surface
  • Dual-Band AR: Visible + MWIR peak optimization
  • DLC Hard Carbon: Sand/rain erosion protection
  • Hydrophobic Top Layer: ≥110° water contact angle
  • Coating Durability per MIL-C-48497A

Recommended Solution: Sapphire + Dual-Band AR + DLC Overcoat for Externally Mounted Pods

Discuss Your Coating Requirement →

Core Technical Specifications

Parameter Specification
Material Single Crystal Sapphire (Al₂O₃)
Crystal Orientation C-plane (0001) / A-plane (11-20) / R-plane (1-102)
Dimension Range Ø5 mm – Ø300 mm; custom rectangular & shaped profiles
Thickness Range 0.5 mm – 10 mm, custom thickness available
Surface Quality 60-40 to 20-10 per MIL-PRF-13830B
Surface Flatness λ/10 to λ/4 @ 633 nm
Clear Aperture ≥ 90% of central diameter
Transmission ≥85% avg. UV–MWIR; ≥82% LWIR (with AR coating)
Coating Option Custom BBAR, dual-band, multi-layer dielectric AR, DLC, hydrophobic
Operating Temperature -60°C to +500°C continuous
Edge Processing Fine ground, polished, beveled edge, or step-mount profile
Prototype MOQ 1 piece
Prototype Lead-time 2–3 weeks*
Mass Production Lead-time 4–6 weeks*

*Subject to crystal orientation, geometry, coating complexity and quantity.

Typical Sapphire EO/IR Window Applications

Airborne EO/IR Turrets & Sensor Pods

Application

Forward-looking and gimbal-mounted sensor packages on fixed-wing and rotary-wing platforms. Windows must survive combined thermal, pressure and aerodynamic loads while maintaining boresight stability.

Our Solution

C-plane sapphire with dual-band AR coating (visible + MWIR), precision polished to λ/4 flatness, edge-step mount profile for gimbal integration. DLC overcoat option for forward-facing positions.

Typical Outcome

Prototype windows passed environmental qualification, approved for follow-on production batch orders.

UAV & Drone Thermal Imaging Payloads

Application

Weight-optimized sapphire windows for small to medium unmanned aerial vehicles. Thin substrate designs (<3 mm) with edge-mount profiles that minimize mass while preserving optical flatness under vibration.

Our Solution

Thin-profile sapphire substrate with FEA-optimized thickness-to-diameter ratio, BBAR coating for MWIR thermal band, lightweight edge-ground profile for payload integration.

Typical Outcome

Custom samples delivered on schedule, validated under customer UAV vibration and thermal cycling conditions.

Ground-Based Surveillance & Target Acquisition

Application

Fixed and vehicle-mounted thermal imaging stations for perimeter surveillance, border monitoring and artillery forward observation. Windows sized for wide-field-of-view sensors and specified for continuous outdoor exposure.

Our Solution

Large-diameter sapphire window (up to Ø300 mm) with hydrophobic top layer for rain shedding, BBAR coating for multi-band visible+MWIR operation, fine-ground edge for flange mounting.

Typical Outcome

Production windows passed 500-hour salt spray and 10-day humidity testing, approved for continuous outdoor deployment.

Missile Seeker & Guidance Windows

Application

High-speed aerodynamic windows for infrared homing seekers. Hemispherical and ogive dome geometries manufactured from single-crystal sapphire boules with precision centering and wall thickness uniformity.

Our Solution

Sapphire dome precision ground and polished from oriented boule, multi-layer AR coating optimized for seeker MWIR/LWIR band, strict wall thickness uniformity and centering tolerance control.

Typical Outcome

Qualification domes passed thermal shock and aerodynamic heating simulation, approved for low-rate initial production.

From Sapphire Boule to Finished EO/IR Protective Window

01 Engineering Drawing Review

Professionally verify drawing dimensions, tolerance, crystal orientation, spectral band requirements and coating specifications to formulate customized production plans.

02 Crystal Orientation Selection

Select matched crystal orientation: C-plane (0001) for minimum birefringence, A-plane (11-20) for high thermal conductivity, R-plane (1-102) for specific polarization requirements.

03 Precision Slicing from Sapphire Boule

Oriented slicing from single-crystal sapphire boule according to customized thickness standards to ensure blank dimensional accuracy and crystal alignment.

04 Custom CNC Machining

Complete personalized processing: outer diameter shaping, edge steps, mounting flanges, alignment flats, D-shapes and irregular contour shaping for your housing assembly.

05 Grinding & Lapping

Precision control of thickness, flatness and wedge, eliminate subsurface damage from slicing, prepare surface for final polishing.

06 Precision Polishing

Achieve surface quality from 60-40 to 20-10 per MIL-PRF-13830B and surface flatness from λ/4 to λ/10 @ 633 nm, strict ultrasonic cleaning before coating.

07 Multi-Layer AR Coating

High-vacuum electron-beam evaporation or ion-assisted deposition to apply custom BBAR, dual-band or multi-layer dielectric AR coatings, plus optional DLC hard carbon and hydrophobic top layers.

08 Strict Multi-Dimensional Inspection

Interferometric surface measurement, spectrophotometric transmission scan (0.2–14 μm), surface defect inspection per MIL-PRF-13830B, dimensional verification via CMM or optical profilometer.

09 Export Standard Packaging & Shipment

Protective export-grade packaging with first-article inspection data package to reduce breakage risk during international transportation.

Request Prototype Verification

Why Start With a 1-Piece Sapphire Window Prototype?

01 Verify the Design

Confirm custom dimensions, mounting fit, edge profile and crystal orientation before qualification or production to avoid structural and optical errors.

02 Test Optical & Coating Performance

Evaluate multi-band transmission, surface flatness, coating adhesion and environmental durability under your actual sensor operating conditions.

03 Reduce Program Risk

Validate all technical indicators with low-cost prototype testing before committing to qualification lots or full-rate production sapphire window orders.

Request a 1-Piece Prototype

Not Sure Which Sapphire Configuration You Need?

Your Requirement Recommended Sapphire Solution
General multi-band visible + MWIR EO/IR application C-Plane (0001) Sapphire + BBAR Coating
Polarization-sensitive sensor system C-Plane Sapphire for minimum in-plane birefringence
High thermal conductivity / cooled detector heat spreading A-Plane (11-20) Sapphire Substrate
Discrete visible + MWIR dual-channel sensor Sapphire + Dual-Band AR Coating
LWIR 8–12 μm thermal imaging Thin Sapphire Substrate + LWIR-optimized AR (or ZnSe/Ge alternative)
High sand/rain erosion environment (externally mounted pods) Sapphire + DLC Hard Carbon Overcoat
Outdoor rain shedding / hydrophobic requirement Sapphire + Hydrophobic Top Layer (≥110° contact angle)
High pressure differential / thick window requirement FEA-Optimized Thickness + Step-Mount Edge Profile
Custom holes, cutouts & special-shaped outline Precision CNC Machining before Polishing & Coating
Early-stage R&D / qualification program 1-Piece Custom Sapphire Window Prototype

Still confused about your project configuration? Ask Our Engineers for Free Guidance

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Frequently Asked Questions Before Ordering

Q: What is the difference between C-plane and A-plane sapphire for EO/IR windows?
A: C-plane (0001) sapphire is optically isotropic in the plane of the window, minimizing polarization-dependent transmission variation across the aperture — important for sensors that split or analyze polarization. A-plane (11-20) sapphire offers higher thermal conductivity in the through-thickness direction and may be preferred when the window also serves as a heat spreader for a cooled detector. The appropriate orientation is selected based on your sensor's optical prescription and thermal management architecture.
Q: Can sapphire windows withstand supersonic aerodynamic heating?
A: Yes. Sapphire's melting point of 2,050°C and thermal shock resistance allow it to survive the thermal loads associated with supersonic flight. The limiting factor in most installations is not the sapphire itself but the window mounting system and the sensor's internal thermal management. We can provide thermal FEA data for specific flight profiles to support airframe integration analysis.
Q: What is the minimum achievable thickness for a given diameter?
A: The minimum thickness-to-diameter ratio depends on the pressure differential, mounting configuration (clamped vs. bonded), and acceptable transmitted wavefront error under load. As a starting guideline, a 4:1 aspect ratio (diameter to thickness) is achievable for pressure-sealed flat windows under 1 atm differential with simply supported edges. We perform structural and optical analysis for each window specification to confirm the design meets all requirements.
Q: How do you control birefringence in sapphire windows?
A: Sapphire is a uniaxial birefringent crystal. For polarization-critical windows, C-plane orientation is selected because the extraordinary and ordinary axes are degenerate in this plane, minimizing in-plane birefringence. Residual stress birefringence from crystal growth and fabrication is measured and reported for each window. Typical stress birefringence is below 5 nm/cm for annealed substrates.
Q: What coating durability testing do you perform for aerospace qualification?
A: Coating qualification follows MIL-C-48497A protocols: adhesion (tape test per ASTM D3359), moderate abrasion (eraser rub test, 20 strokes minimum), and humidity (24-hour exposure at 49°C and 95–100% RH). Additional testing per customer specification may include salt fog (ASTM B117), temperature cycling (MIL-STD-810H), and rain erosion. Test reports are provided with qualification shipments.
Q: Can you manufacture rectangular, D-shaped or custom-contour sapphire windows?
A: Yes. CNC machining can realize rectangular, square, D-shaped, and custom contour sapphire windows. Edge step profiles, mounting flanges, and alignment flats can be incorporated into the blank generation process before polishing and coating.
Q: When should I choose sapphire vs. ZnSe or germanium for LWIR applications?
A: Sapphire is preferred when the window must also transmit visible/SWIR/MWIR bands, requires extreme hardness and environmental durability, or operates at high temperatures. ZnSe and germanium offer higher LWIR transmission but are softer, temperature-sensitive and do not transmit visible light. For pure LWIR passive detection, ZnSe or Ge may be more cost-effective; for multi-band or harsh-environment systems, sapphire is the standard choice.
Q: What is the difference between BBAR and dual-band AR coating?
A: BBAR (Broadband Anti-Reflection) is a single coating stack covering two or more continuous sensor bands (typically visible through MWIR) with average reflectance below 1.5% per surface. Dual-band AR is optimized for systems with discrete visible and MWIR channels, providing peak transmission at the specific detector quantum efficiency peaks of each channel. Our engineers recommend the appropriate stack based on your sensor's spectral response requirements.
Q: How long does a custom sapphire window prototype take?
A: Typical prototype lead time is 2–3 weeks after specifications are confirmed. Actual timing depends on crystal orientation, geometry complexity, coating type and inspection requirements. First-article inspection reports including all optical and dimensional data are standard for prototype orders.
Q: What information do you need for quotation?
A: Ideally, send your drawing (CAD/DXF/PDF), crystal orientation preference, dimensions and thickness, surface quality requirement, surface flatness tolerance, spectral bands of interest, coating type, mounting configuration, operating environment, quantity and delivery schedule. Incomplete specifications are acceptable for preliminary engineering evaluation.
Get Custom Quote Now

Request a Custom Sapphire EO/IR Window Quote

Tell us what you need. Our optical engineers will review your requirements and provide a suitable manufacturing solution and quotation.

Free engineering review · 1-piece prototype support · OEM/ODM manufacturing

Have a Sapphire EO/IR Window Project? Let's Review It.

Send your drawing, sample photo, dimensions, crystal orientation or spectral band requirements. You don't need to finalize every specification. Our optical engineering team will provide professional customized manufacturing solutions for your aerospace and defense EO/IR project.

Ask Our Engineers Send Your Drawing Get My Custom Quote

Free engineering review · 1-piece prototype support · OEM/ODM manufacturing

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We supply Industrial Glass, Sapphire Optics, Optical Lenses/Prisms/Filters, Infrared IR Optics, Functional & Display Glass, N-BK7/H-K9L Optical Glass, supporting OEM mass production and laboratory custom prototypes. Flexible MOQ & free sample service available. Fill in the form to download full datasheets and get factory wholesale price within 24 hours.

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What is the minimum order quantity for custom precision optical glass components?

FELIX OPTICAL GLASS offers highly flexible MOQs to support customer projects, including prototype testing, small-batch trial orders, and high-volume production. All products can be fully customized to your drawings, tolerances, and application standards. Please send us your specifications, and we will reply within 1-5 hours and provide an accurate quotation after careful evaluation within 1-2 days.

Can I get free glass samples for testing before bulk order?

Yes, our FELIX GLASS factory supports sample testing for a wide range of precision optical glass components and assemblies. The lead time for sample production is 3 to 7 working days. Please contact us today to arrange samples and obtain a customized solution that meets your needs.

What is the production lead time for custom optical glass components?

A: The production cycle for standard samples is 3-10 working days, while mass production requires 15-35 working days, depending on the complexity of the product and the order quantity. We provide reliable precision optical glass components and fast delivery services for orders from industries such as defense, industrial equipment, medical devices, shipbuilding, robotics, automotive, and aerospace. Please submit your project details so we can provide you with an accurate delivery schedule.

Are your optical glass products ISO, CE and RoHS certified?

All precision optical glass components from FELIX OPTICAL GLASS comply with ISO quality system standards as well as CE and RoHS requirements. We provide comprehensive test reports, spectral graphs, material certificates, and inspection documents for customer review. Please feel free to request complete certification details and a formal quotation at any time.

Do you offer one-stop custom optical glass processing services?

Yes. We offer a full range of precision optical glass component processing services, including CNC machining, precision grinding, optical polishing, chemical/physical tempering, vacuum coating (AR anti-reflective coating, AF anti-fingerprint coating, AG anti-glare coating, IR infrared coating), and screen printing. From raw materials to finished products, every step is completed in our own factory. Please tell us your needs, and we will provide you with the most cost-effective solution.

CONTACT US NOW FOR A QUOTE
We will respond promptly within 1 to 5 hours and provide an optimal, formal quotation within 1 to 2 days. Partnering with us is the smartest choice—start a mutually beneficial partnership today!
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With 19 years of experience as a precision optical glass expert, we provide comprehensive and satisfactory customized solutions.

✔ROHS CE certified ISO9001:2005 quality management system
✔Professional team over 19 years’ experience under Japanese management system
✔Help over 2000+ companies to make prototypes into mass production successfully
✔Challenge the 100% on time delivery goal 100% full inspection report
✔Cost-down solutions for over 2000+ companies with success
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✔Support free samples (quick sample production) Small quantity (100-1000pcs) available

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james@felixglass.com

+86 185 6503 2888

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