Custom Optical Windows | Sapphire, Quartz, Fused Silica & Vacuum Viewports

Custom sapphire, quartz, fused silica, CaF₂, MgF₂, ZnSe, and optical glass windows manufactured to your drawing or application requirements.

Design Realized provides custom optical windows for scientific research, vacuum systems, laser systems, spectroscopy, imaging, radiation detection, semiconductor tools, and harsh-environment applications. We support one-off prototypes, small-batch R&D builds, and volume production.

Whether you need a simple round window, a vacuum-sealed viewport, a high-transmission UV window, a sapphire pressure window, or a coated laser-grade optic, our team can help evaluate material, geometry, polishing, coating, and mounting options.

Custom Optical Window Capabilities

We manufacture optical windows in a wide range of materials, sizes, shapes, and surface specifications.

Available Materials

• Sapphire – high strength, excellent hardness, high-temperature stability, chemically resistant
• Quartz / Fused Silica – excellent UV transmission, low autofluorescence, good thermal stability
• BK7 / Optical Glass – cost-effective for visible and general optical applications
• CaF₂ – UV to IR transmission, commonly used for spectroscopy and laser systems
• MgF₂ – deep-UV transmission, durable fluoride window option
• ZnSe – IR and CO₂ laser applications
• Silicon / Germanium – IR optical windows and thermal imaging applications
• Custom optical crystals – available upon request

Typical Applications

Our custom optical windows are widely used in:

• High-vacuum and UHV chambers
• Laser systems and beam delivery
• Spectroscopy and LIBS systems
• Photocatalysis and photochemical reactors
• Plasma systems
• Semiconductor and thin-film deposition tools
• Cryogenic systems
• Radiation detectors and scintillator assemblies
• Imaging systems and camera protection windows
• Harsh-environment optical access ports
• UV, visible, NIR, and IR optical instruments

Custom Design Options

We can support a wide range of custom specifications, including:

• Round, square, rectangular, or irregular shapes
• Custom diameter, thickness, and aperture size
• Single-side or double-side optical polishing
• Flatness and parallelism control
• Wedge angle control
• Chamfered, beveled, or rounded edges
• Step windows and recessed geometries
• Drilled holes or slots
• AR, HR, metallic, conductive, or protective coatings
• Vacuum-compatible sealing options
• Metalized or brazed window assemblies
• Custom holders, flanges, or mechanical mounts

If you already have a drawing, STEP file, or hand sketch, we can review it and provide a quotation.

Vacuum Viewports & Sealed Window Assemblies

For vacuum and UHV applications, we can provide optical windows integrated with mechanical or metal assemblies.

Common options include:

• Sapphire viewports
• Quartz / fused silica viewports
• CF, KF, ISO, or custom flange-mounted windows
• Glass-to-metal sealing
• Brazed or bonded window assemblies
• High-temperature compatible designs
• Custom leak-test and inspection options

For high-vacuum or UHV systems, please provide the pressure range, temperature range, flange type, window clear aperture, and whether bakeout is required.

Laser & Spectroscopy Windows

For laser and spectroscopy applications, material and coating selection are critical. We can provide windows optimized for specific wavelength ranges.

Typical wavelength ranges include:

• Deep UV
• UV-visible
• Visible
• NIR
• Mid-IR
• CO₂ laser wavelength

Available optical specifications may include:

• High transmission at target wavelength
• AR coating at one or multiple wavelengths
• Low fluorescence material options
• High laser damage threshold coating options
• Tight surface quality and flatness requirements
• Low wedge or intentional wedge design

Please share the operating wavelength, laser power or energy density, beam diameter, pulse width, and angle of incidence when requesting a quote.

Example Custom Window Types

Sapphire Windows

Sapphire windows are ideal for applications requiring high mechanical strength, scratch resistance, thermal stability, or chemical resistance. They are commonly used in vacuum chambers, high-pressure cells, combustion diagnostics, laser systems, and harsh environments.

Fused Silica / Quartz Windows

Fused silica and quartz windows are widely used for UV transmission, spectroscopy, photochemistry, and precision optical systems. They provide excellent optical clarity and thermal stability.

CaF₂ and MgF₂ Windows

Fluoride windows are commonly used for UV, deep-UV, and IR optical applications. These materials are often selected for spectroscopy, excimer laser systems, and broadband transmission requirements.

ZnSe Windows

ZnSe windows are commonly used for IR and CO₂ laser systems. They are suitable for thermal imaging, IR spectroscopy, and laser protection windows.

Quality Control & Inspection

Depending on project requirements, inspection options may include:

• Dimensional inspection
• Surface quality inspection
• Flatness measurement
• Parallelism measurement
• Transmission testing
• Coating verification
• Visual inspection under controlled lighting
• Helium leak testing for sealed viewport assemblies
• Packaging suitable for optical components

Information Needed for Quotation

To provide an accurate quotation, please send as much of the following information as possible:

1. Material, such as sapphire, quartz, fused silica, CaF₂, MgF₂, ZnSe, or optical glass
2. Shape and dimensions
3. Thickness
4. Quantity
5. Required wavelength range
6. Surface quality requirement, if known
7. Flatness and parallelism requirement, if known
8. Coating requirement, such as AR, HR, protective coating, or no coating
9. Operating environment, such as air, vacuum, high temperature, pressure, chemical exposure, or radiation
10. Drawing, STEP file, or sketch if available

If you are unsure about the best material or specification, our team can help recommend a practical option based on your application and budget

Prototype and Small-Batch Friendly

Many scientific and engineering projects require only one or a few custom optical windows. We support low-volume orders and prototype builds for universities, national laboratories, startups, and industrial R&D teams.

We can also support repeat production after the design is validated.