1. Filters sub-system for QUBIC
For Technological Demonstrator (T.D.)
And
For Final Instrument (F.I.)
QUBIC Collaboration Meeting, January 18/19, Milano

2. Status of the sub-system : #1
Status of the Optical Filtering sub-system
All design and manufacture is performed in-house, using standard Cardiff modelling and manufacture processes.
Spectral tests will be performed with FT spectrometers and VNA; cryogenic cycling; mechanical cutting and mounting - all performed at Cardiff.
Modelling for all components is finished (filters) or well underway (HWP), however there are mechanical issues for the F.I. to be resolved.
Manufacture of T.D components well underway and achievable with current manufacture capabilities.
Manufacture of F.I components requires a technological upgrade to current Cardiff infrastructure to facilitate production of mm devices.
Sub-system components still requiring design:
Dichroic for F.I. needs urgent consideration. Current issues relate to current non-circular design, maintaining flatness, angle of incidence, large size.
To guarantee flatness through thermal cycling an ‘air-gap’ filter must be used. Must be circular. How much QUBIC redesign is required?
However air-gap imposes size limitations, so we may have to resort to ‘hot-pressed’. Will still have to be circular because of thermal contraction.
Cardiff dichroics only designed for use at 22.5 AoI, loss in performance and diffraction issues beyond this.
Fundamental optical design for dichroic still has flexibility (high-pass or low-pass version); decision based on which will gives best performance.
Design for HWP is underway and will be fine-tuned from recent results on another instrument.
Requires discussion at Instrument Design and Cryostat Design level.
For T.D. Interfaces are being approved ready for manufacture.
QUBIC Collaboration Meeting, January 18/19, Milano

3. Status of the sub-system : #2
Technology Demonstrator (T.D.)
The optical design for T.D. filters complete.
Thermal Filters manufactured and tested. Mounting rings in manufacture.
Focal plane and edge filters in manufacture now.
Small issue to ensure no gaps between focal plane filter stack (fringing).
All components have been/will be spectrally characterized at Cardiff.
Staggered delivery to Roma for T.D. integration. Small slip to schedule.
Neutral density filter also required. Need final confirmation that 200mm OK.
T.D. is single band and does not include a dichroic element.
Final Instrument (F.I).
Optical design is not a problem, but technical capability and mechanical design will cause delay to Annex 2 schedule.
Current activity to scale-up all cleanroom process for 500mm devices awaits confirmation of further ESA funding. Current Cardiff schedule sees manufacture of components from September Manufacture times for larger devices will be longer that our 300mm versions; not a clear picture yet of how long….
Solution for Dichroic to be found.
QUBIC Collaboration Meeting, January 18/19, Milano

4. Interfaces with other sub-systems
Mechanical interfaces with other systems.
Filters interface via support rings or clamps.
Drawing for thermal and hot-pressed filters in place. Can be frozen.
Dichroic far from finalised. Cannot be frozen. Drawing of typical mount provided.
HWP integrates to rotator design with APC – to be finalized.
QUBIC Collaboration Meeting, January 18/19, Milano

5. Test, Delivery, Assembly, Calibration Operations
Tests of the sub-system in your premises before delivery at APC or ROMA:
All Cardiff Filters are spectrally characterized in transmission at room temperature.
We test against modelled performance for in-band transmission, frequency edge position, out-of-band rejection and harmonic leaks.
In addition we perform basic cold testing (nitrogen shock) on all components to ensure no delamination of multi-layered components.
If filter does not meet spectral specifications (within 2% of edge frequency and modelled in-band transmission) or delaminates, it fails.
Delivery to APC or ROMA:
Filters will be suitably packaged for delivery to APC. Hot-pressed filters are reasonably robust. Thin (thermal) filters, polarizers will have protective outer sheets. Any large air-gap device (dichroic?) will require a special shipping box.
Assembly Operations in APC or/and ROMA:
Hot-pressed filters can be freely handled, with standard care take not to dirty filter or scratch it. Grease can be removed with IPA.
Thermal filters, polarizers, air-gap devices are more fragile (2-4 micron polymer sheets) and can easily be damaged by screwdrivers!
Currently no plan or resource to send Cardiff staff to APC.
Calibration Operations at APC:
We anticipate that there will be ongoing discussion regarding the cryostat thermal environment and detector performance during integration and calibration.
QUBIC Collaboration Meeting, January 18/19, Milano

6. ATRIUM and Documentation
We will upload transmission & performance files for all filter component tests performed at Cardiff.
QUBIC Collaboration Meeting, January 18/19, Milano

7. Last news, program for 2017 and other useful information
The biggest programme item for Cardiff is the upgrade of our manufacture chain for production of 500mm devices (current limit is 320mm).
We can perform lithography up to 500mm, but cannot bond multi- layer devices until the build and installation of a bespoke Filter Oven. This is part funded by ESA.
There will also be the need to procure all relevant photolithographic master plates. This is costly and it is hoped to spread this cost between many projects requiring a similar development.
QUBIC Collaboration Meeting, January 18/19, Milano

8. Budget (excluding salaries)for T.D. + F.I.
Spendings (type and amount)
Funding (source and amount)
Status of funding (granted / under examination)
2017
Master plates tbd
tbd
Under examination
2018
QUBIC Collaboration Meeting, January 18/19, Milano

9. QUBIC Collaboration Meeting, January 18/19, Milano
Manpower No funded Cardiff staff effort, has to fit within our rolling grant development activities!
Name and responsibility
% FTE 2017
% FTE 2018
Giampaolo Pisano (design)
Carole Tucker (manufacture & test)
Peter Ade (design & test)
Nicola Owens (C/R tech)
Agnieszka Kasparek (C/R tech)
TOTAL FTE
QUBIC Collaboration Meeting, January 18/19, Milano

10. QUBIC Collaboration Meeting, January 18/19, Milano
Risks analysis
Delay of Cardiff facility upgrade for pressing of 500mm elements.
Discussions with ESA on 16/1/17 for increased resource for this.
Schedule and internal resource already identified.
Hardware development well underway.
Provision of large size photolithographic master plates and their cost. Affects thermal filters in particular – current best price is £24K per plate.
Sharing of cost between a number of projects wanting larger scale devices.
Any single apparatus failure or skilled staff loss during manufacture phase.
Duplication of equipment prevents cessation of work.
Crossover of staff expertise, but no resource to replace.
QUBIC Collaboration Meeting, January 18/19, Milano

11. Annex 1: list of main-sub-system and WP leaders
QUBIC Collaboration Meeting, January 18/19, Milano

12. Annex 2 : Target schedule
QUBIC Collaboration Meeting, January 18/19, Milano

13. Annex 3: examples of possibly needed major tools or utilities
High voltage (380 V) power
Cold water
Liquid or gaseous N2 / He
Compressed air
Clean air laminar flow / clean room / conditioned air
Assembly Hall
Mechanical workshop
IT network or Wifi
Chemicals
ESD equipments
Crane or heavy handling systems
Metrology systems (Faro, MMT, Laser…)
VNA
Calibration source
Mount (or fake)
Vacuum systems (including degassing)
Acquisition systems
Computers / data acq. systems
Electrical test with probe station
QUBIC Collaboration Meeting, January 18/19, Milano