Ron Hu

Microshutter array system for James Webb Space Telescope

We have developed microshutter array systems at NASA Goddard Space Flight Center for use as multi-object aperture arrays for a Near-Infrared Spectrometer (NIRSpec) instrument. The instrument will be carried on the James Webb Space Telescope (JWST), the next generation of space telescope, after the Hubble Space Telescope retires. The microshutter arrays (MSAs) are designed for the selective transmission of light from objected galaxies in space with high efficiency and high contrast. Arrays are close-packed silicon nitride membranes with a pixel size close to 100x200 μm. Individual shutters are patterned with a torsion flexure permitting shutters to open 90 degrees with minimized stress concentration. In order to enhance optical contrast, light shields are made on each shutter to prevent light leak. Shutters are actuated magnetically, latched and addressed electrostatically. The shutter arrays are fabricated using MEMS bulk-micromachining and packaged utilizing a novel single-sided indium flip-chip bonding technology. The MSA flight system consists of a mosaic of 2 x 2 format of four fully addressable 365 x 171 arrays. The system will be placed in the JWST optical path at the focal plane of NIRSpec detectors. MSAs that we fabricated passed a series of qualification tests for flight capabilities. We are in the process of making final flight-qualified MSA systems for the JWST mission.

Microshutter arrays for near-infrared applications on the James Webb Space Telescope

Magnetically actuated MEMS microshutter arrays are being developed at the NASA Goddard Space Flight Center for use in a multi-object spectrometer on the James Webb Space Telescope (JWST), formerly Next Generation Space Telescope (NGST). The microshutter arrays are designed for the selective transmission of light with high efficiency and high contrast. The JWST environment requires cryogenic operation at 45K. Microshutter arrays are fabricated out of silicon-on-insulator (SOI) wafers. Arrays consist of close-packed shutters made on silicon nitride (nitride) membranes with a pixel size of 100 × 100 m. Individual shutters are patterned with a torsion flexure permitting shutters to open 90°, with a minimized mechanical stress concentration. Shutters operated this way have survived fatigue life test. The mechanical shutter arrays are fabricated using MEMS technologies. The processing includes a multi-layer metal deposition, patterning of shutter electrodes and magnetic pads, reactive ion etching (RIE) of the front side to form shutters in a nitride film, an anisotropic back-etch for wafer thinning, and a deep RIE (DRIE) back-etch, down to the nitride shutter layer, to form support frames and relieve shutters from the silicon substrate. An additional metal deposition and patterning has recently been developed to form electrodes on the vertical walls of the frame. Shutters are actuated using a magnetic force, and latched electrostatically. One-dimensional addressing has been demonstrated.

Complex MEMS device: microshutter array system for space applications

A complex MEMS device, microshutter array system, is being developed at NASA Goddard Space Flight Center for use as an aperture array for a Near-Infrared Spectrometer (NirSpec). The instrument will be carried on the James Webb Space Telescope (JWST), the next generation of space telescope after Hubble Space Telescope retires. The microshutter arrays (MSAs) are designed for the selective transmission of light with high efficiency and high contrast. Arrays are close-packed silicon nitride membranes with a pixel size close to 100x200 &mgr;m. Individual shutters are patterned with a torsion flexure permitting shutters to open 90 degrees with a minimized mechanical stress concentration. Light shields are made on to each shutter for light leak prevention so to enhance optical contrast. Shutters are actuated magnetically, latched and addressed electrostatically. The shutter arrays are fabricated using MEMS bulk-micromachining technologies and packaged using single-sided indium flip-chip bonding technology. The MSA flight concept consists of a mosaic of 2 x 2 format of four fully addressable 365 x 171 arrays placed in the JWST optical path at the focal plane.

Silicon-based antenna-coupled polarization-sensitive millimeter-wave bolometer arrays for cosmic microwave background instruments

We describe feedhorn-coupled polarization-sensitive detector arrays that utilize monocrystalline silicon as the dielectric substrate material. Monocrystalline silicon has a low-loss tangent and repeatable dielectric constant, characteristics that are critical for realizing efficient and uniform superconducting microwave circuits. An additional advantage of this material is its low specific heat. In a detector pixel, two Transition-Edge Sensor (TES) bolometers are antenna-coupled to in-band radiation via a symmetric planar orthomode transducer (OMT). Each orthogonal linear polarization is coupled to a separate superconducting microstrip transmission line circuit. On-chip filtering is employed to both reject out-of-band radiation from the upper band edge to the gap frequency of the niobium superconductor, and to flexibly define the bandwidth for each TES to meet the requirements of the application. The microwave circuit is compatible with multi-chroic operation. Metalized silicon platelets are used to define the backshort for the waveguide probes. This micro-machined structure is also used to mitigate the coupling of out-of-band radiation to the microwave circuit. At 40 GHz, the detectors have a measured efficiency of ∼90%. In this paper, we describe the development of the 90 GHz detector arrays that will be demonstrated using the Cosmology Large Angular Scale Surveyor (CLASS) ground-based telescope.

Fabrication of Superconducting Vacuum-Gap Crossovers for High Performance Microwave Applications

The fabrication of low-loss wide-bandwidth superconducting vacuum-gap crossovers for high performance millimeter wave applications is described. In order to reduce ohmic and parasitic losses at millimeter wavelengths a vacuum gap is preferred relative to dielectric spacer. Here, vacuum-gap crossovers were realized by using a sacrificial polymer layer followed by niobium sputter deposition optimized for coating coverage over an underlying niobium signal layer. Both coplanar waveguide and microstrip crossover topologies have been explored in detail. The resulting fabrication process is compatible with a bulk micromachining process for realizing waveguide coupled detectors, which includes sacrificial wax bonding, and wafer backside deep reactive ion etching for creation of leg isolated silicon membrane structures. Release of the vacuum-gap structures along with the wax bonded wafer after deep reactive ion etching is implemented in the same process step used to complete the detector fabrication.

MEMS Microshutter Arrays for James Webb Space Telescope

MEMS microshutter arrays (MSAs) are being developed at NASA Goddard Space Flight Center for use as an aperture array for the Near-Infrared Spectrometer (NirSpec). The instruments will be carried on the James Webb Space Telescope (JWST), the next generation of space telescope after Hubble Space Telescope retires. The microshutter arrays are designed for the selective transmission of light with high efficiency and high contrast. Arrays are close-packed silicon nitride membranes with a pixel size of 105x204 μm. Individual shutters are patterned with a torsion flexure permitting shutters to open 90 degrees with a minimized mechanical stress concentration. Light shields are made on each shutter for light leak prevention to enhance optical contrast. Shutters are actuated magnetically, latched and addressed electrostatically. The shutter arrays are fabricated using MEMS technologies. Single-side indium flip chip bonding is performed to attach microshutter arrays to substrates.

Thermal-Stress Control of Microshutter Arrays in Cryogenic Applications for the James Webb Space Telescope

We report on methods to minimize thermally-induced deformation in a MEMS-based reconfigurable aperture. The device is an enabling component of the Near-Infrared Spectrometer, a principle instrument on NASA’s James Webb Space Telescope. The Microshutter Array consists of 384x175 individually addressable shutters which can be magnetically rotated 90° into the plane of the array and electrostatically latched open. Each shutter is a 100x200 μm rectangular membrane suspended by a small neck region and torsion flexure. The primary materials in the shutter are a 5000Å Si3N4 layer for mechanical rigidity, 2000Å Al for opacity and electrostatic latching, and 2200Å Co90Fe10 for magnetic actuation. This multi-layer stack presents a challenge due to the operating temperatures required for the device: both room temperature (300K) and cryogenic temperature (30K). Thermal expansion of the materials causes the shutters to bow out of plane excessively, which can prevent actuation of the shutters, cause damage to portions of the array, and allow light leakage around closed shutters. Here we present our investigation of several methods to prevent microshutter bowing including deposition of additional materials on the shutters to create a symmetrical layer stack and replacing the current stack with low-coefficient of thermal expansion materials. Using shutter-size suspended cantilever beams as a rapid-development test bed, we have reduced out-of-plane bowing between 300K and 30K to 10% or better. We are currently applying these results to microshutter arrays to develop shutters that remain flat from room temperature to cryogenic temperature while retaining the required mechanical, optical, and magnetic properties.