In November 2012 Prime Photonics expanded into a newly remodeled fit-for-purpose facility that includes 16,250 sq.ft. of office, laboratory, and manufacturing space. Prime Photonics maintains well equipped mechanical, optical, electrical, materials/chemistry, computer, test, and manufacturing labs that support the wide range of research and development activities performed by Prime.
Modeling, Simulation, and Software
Prime Photonics maintains a powerful suite of modeling, simulation and engineering design software as well as numerous work stations. Major software tools include SolidWorks, AutoCAD, ANSYS, Altium PCB design and layout, Zemax Optical and Illumination Design, Visual Studio, MATLAB, and LabVIEW.
Test and Measurement
Major test and measurement equipment includes a high pressure calibrator, LabWorks Shaker Table System with heating system, Thermotron environmental test chamber, bench top wind tunnel with 6” x 6” test chamber and up to 40 m/s flow velocity, high temperature (1900C-capable) furnaces, vibration-isolated optical tables, high-resolution optical spectrum analyzers, optical beam profiler, programmable optical sources, computer-controlled laser diode drivers, swept frequency laser optical analyzers, polarization state analyzer, computer-controlled micropositioners, precision voltmeters, oscilloscopes, and networked data acquisition systems.
In support of rotor blade sensor calibration and development, as well as fan, compressor and turbine health monitoring technologies, Prime Photonics has developed a strong spin rig test capability. Current rigs include the Clearance Validation Spin rig which can support up to 8.5” rotors, the Active Vibration Spin Rig which includes a 10-channel slip ring for operation of piezeoelectric bimorph blades, strain gauges and piezeoelectric sensors, the Dynamic Research Rig (DR3) high temperature spin rig which has an 11.9” inside diameter shroud and can be used for testing up to 860F (460C), and High Speed Spin Rig supporting operating speeds up to 25,000 RPM with up to 12 blade tip timing sensors at a 30 degrees spacing. Currently under development are the Foreign Object Damage (FOD) spin rig with realistic 3D airfoil blade geometry with high speed camera and the Compressor Rotor Spin Rig which will support both synchronous and asynchronous blade vibration excitation.
Prime Photonics maintains a suite of magnetic sources and characterization instruments. We are able to generate steady-state and pulsed magnetic fields with a wide range of strengths – from several Gauss to 10 Tesla. Additionally, we have the capability to characterize the magnetic properties of materials at various bias levels and excitation frequencies. Our toolset allows for determination of saturation magnetization, permeability, and Barkhausen noise for bulk or powdered samples over a broad temperature range. Specific equipment includes a SVS Labs EMU-50 1.5 Tesla DC electromagnet, FW Bell 5180 Gauss/Tesla Meter, dual coil magnetometer, custom-built vibrating sample magnetometer (VSM) with sample temperature control, zero-gauss shielded chamber, and Bitter coil with 200 microsecond pulses of up to 10 Tesla.
Materials and Chemistry
Large volume vacuum chamber for thermal deposition, diffusion bonding, vacuum brazing, processing of ceramics and sapphire structures, and high temperature vacuum processes. Materials characterization tools such as polishing supplies and a differential interference contrast (Nomarski) microscope. Prime Photonics also operates a comprehensive wet chemistry lab with two fume hoods.
Mechanical and Assembly
Prime Photonics has an array of optical fiber assembly equipment including Fujikura fusion splicers, Nikon fiber inspection equipment and a specialized polishing system for processing sapphire and ceramic components. Prime Photonics has a fully outfitted prototyping machine shop including a Tormach 1100 4-axis vertical mill CNC machine, Elderfield & Hall micro-TIG / plasma welding lathe, high power Excimer UV laser, two MakerBot 3D printers with customized print heads a Morntech 60W CO2 laser machining station with 12” x 20” machining bed, 4.2 kW Ambrell vacuum induction brazing station, Oxy-Propane torch brazing station, and high-vacuum/high-temperature brazing and evaporative metal deposition station.
All Prime facilities meet the necessary local, state, and federal environmental laws and regulations pertaining to airborne emissions, waterborne effluents, external radiation levels, outdoor noise, solid and bulk waste disposal practices, and handling and storage of toxic and hazardous materials.