Evaluating the use of self-assembled monolayer (SAM) release coatings for replicated optics

Abstract

Carbon fiber-reinforced composite replicated mirrors offer weight savings, higher stiffness, tailorable CTEs, higher thermal conductivities, and excellent damage tolerant mechanical properties in comparison to traditionally processed glass mirrors. These mirrors can also be rapidly manufactured by replicating the surface of a high-precision glass mandrel multiple times. The mold release coating used is critical and must be on the molecular scale, uniform, and exhibit low adhesion in order to produce high-fidelity replication. This study investigates the use of a self-assembled monolayer (SAM) as the mold release agent for the manufacture of replicated mirrors. We have synthesized and tested perfluoropolyether (PFPE) coatings formed on glass substrate via self-assembly. Ellipsometry, X-ray photoelectron spectroscopy, and atomic force microscopy were used to characterize the morphology, thickness uniformity and the chemical profile of the coatings. The release force necessary to remove the replicated surfaces from the mandrel is critical and was directly related to the surface distortion of the replica. The release force increased with each successive replication due to pinholes and defects. Incorporating a secondary, lower molecular weight SAM reagent significantly reduced both surface agglomeration and transfer of SAM material to the replicated resin surface. A 60% reduction in the replica release force and a 50% improvement in the replica surface figure were achieved due to reductions in the defect density of the SAM coating.