Case Study: High-Precision Optical Domes for Extreme Conditions
Introduction: Why Extreme Environments Demand Better Optics
From deep-sea exploration to aerospace navigation, optical systems are increasingly deployed in environments where failure is not an option. Protecting cameras, sensors, and imaging equipment requires components that can handle high pressure, temperature swings, and mechanical stress—without compromising image quality.
That’s where optical domes (or dome windows) excel. With dual curved surfaces, they enable wide fields of view while minimizing distortion, ensuring sensors and lenses perform reliably even in unforgiving conditions.
Project Overview: A Custom Dome for R&D Under Pressure
Shanghai Optics was tasked with designing and manufacturing a three-dome assembly for a research application:
- Configuration: Two identical domes bonded and clamped with a titanium ring, enclosed by a larger protective dome.
- Operating Conditions: High pressure exceeding 3 bar and a 60°C temperature differential.
- Engineering Challenge: Managing thermal expansion, tight tolerances (±50 μm), and mechanical shear forces in a compact clamping area.
The result was a robust optical solution that maintained structural integrity and optical performance in conditions that push materials and designs to their limits.
Key Engineering Factors in Optical Dome Design
- Coatings for Performance
Anti-reflective coatings reduced reflection losses to less than 0.2%, ensuring clear transmission.
- Material Selection
Choosing materials with the right thermal expansion properties and mechanical strength was critical. For this project, chalcogenide glass balanced durability with optical clarity.
- Curvature Optimization
Dome curvature directly affects field of view and image sharpness. Engineers optimized curvature to achieve distortion-free imaging under pressure.
- Mounting & Sealing
Titanium rings provided mechanical stability while protecting against contamination and ensuring airtight sealing.
- Environmental Resilience
The domes were engineered to withstand both harsh underwater conditions and temperature extremes, making them versatile across industries.
Specifications of the Optical Domes
- Dimension: Ø 80mm
- Thickness: 4mm
- Material: Chalcogenide glass
- Coating: Anti-reflection Coating (<0.2%)
Solving the Challenges
Shanghai Optics overcame the toughest constraints by:
- Using dual dome + titanium clamping assembly for mechanical stability.
- Applying coatings that boosted optical performance while reducing transmission loss.
- Engineering tolerances down to ±50 μm to ensure reliability under load.
- Testing designs extensively to confirm resilience in pressure and thermal extremes.
This project demonstrated not only the strength of the materials and coatings, but also Shanghai Optics’ engineering expertise in precision assemblies.
Why It Matters
High-precision optical domes are crucial in:
- Underwater Imaging – Protecting deep-sea cameras and sensors.
- Aerospace Navigation – Maintaining clarity in high-altitude, high-speed conditions.
- Surveillance Systems – Wide field of view with minimal distortion.
- Scientific Instruments – Accurate imaging in demanding environments.
Conclusion: Engineering for the Extreme
By combining advanced material science, tight tolerance machining, and innovative assembly techniques, Shanghai Optics delivered a dome solution that thrives in extreme conditions.
Our work not only solves today’s challenges but also sets a new benchmark for protective optical enclosures in research, defense, aerospace, and marine industries.
Need an optical solution for harsh environments? Contact Shanghai Optics today to discuss how our domes can safeguard your mission-critical systems.
