High demand for infrared technology on battlefield.

Advances in manufacturing technology are allowing a new generation of infrared imaging devices to reach the battlefield in record numbers, according to military and industry sources.

Lighter materials and improved optics also have been instrumental in moving high performance and traditionally larger systems off vehicles and onto soldiers' weapons and handheld devices.

Second generation forward looking infrared (FLIR) sensors, with greater resolution and ability to penetrate sand and dust, have been installed on half the fleet of Abrams tanks and Bradley fighting vehicles, said Col. Mike Bowman, the Army's project manager for night vision, reconnaissance, surveillance and target acquisition.

"This is really a manufacturing breakthrough," Bowman said.

Infrared receptors require the growth of crystals, which is a difficult process that involves the use of a 'clean room' environment that is pure of all air particles or contaminants.

"They could only make these receptors in small quantities in the 1990s, and there was a lot of wasted materials," Bowman said. "Now they can mass produce them."

The ability of industry to produce advanced IR systems quickly is manifest in today's combat zones. One example is the long-range advanced surveillance sensor system (LRAS3) infrared system. Soldiers in Iraq equipped with the LRAS3 are able to see through the sand with enough details to positively identify targets, such as enemy tanks, he noted. "It gives the soldiers stand-off range a lot further than enemy systems."

The system will be adapted to be used by fire-support teams. By adding a laser designator to guide bean>riding munitions, a new tool for coordinating artillery has been created. Prototypes of the fire support sensor system (FS3) have been developed by the program executive office for intelligence, electronic warfare and sensors, Bowman said.

Also in the works in Bowman's shop is the 3rd generation LRAS3, to be tested in 2006. The next- generation systems will use receptors more liberally, display data on high-definition television screens and combine mid- and long-wave infrared beams.

"We're three years nut from fielding deployable hardware," Bowman said. "I feel it will be the mainstay for 2010 systems."

Infrared systems come in two forms, cooled and uncooled. A system with a mechanism for controlling heat is more sensitive to slight temperature variations.

Uncooled systems are portable, cheaper and have a shorter range. They are used as warning sensors by logistics vehicles or in infantry gun sights.

Another development has been the introduction of sensor fusion technology, which combines night-vision and IR imagers into one system. The goal is to provide a single system that penetrates smoke, fog, shadows and moonless conditions.

"New advancements continue to be made in smaller electronics and power management that will result in lighter and more capable systems," said Patricia Perlini, spokesperson for Raytheon, the manufacturer of LRAS3. "Fusion of image intensifiers and thermal imagers in a lightweight, head-mounted package will advance the current goggles that are being worn by troops today."

The enhanced night vision goggle will begin low-rate production next year.

This flood of activity is stressing manufacturers. Raytheon--with a $200 million contract with the Army for thermal sights--is reacting to this pressure by ramping up production, a feat sometimes hampered by the limits of the subcontractors who supply the specialty parts. The demand is so high that Raytheon is paying the cost of modernizing suppliers' facilities, officials said.

"Several key suppliers who make unique components for the thermal weapons sights required investment in capital and resources to meet the demand," said Perlini.

Raytheon spent approximately $4 million to evaluate and improve the production facilities of 30 primary and sub-tier parts suppliers, said Jon Piatt, the company's acting director of business development for soldier weapon sensor systems.

"It's a small price to pay to increase the flow from the suppliers," Piatt said. "It's a significant challenge when you're dealing with a supply chain from around the country."

The process started with on-site visits to explore how and where production bottlenecks were occurring. "Many of the smaller suppliers don't have the resources to do a full evaluation," said Piatt.

Raytheon also spent $2.9 million to expand its own facilities to improve the electronics that enhance image quality.

Weapon sight production has grown over the course of a year from about 450 systems per month to more than 1,100 in September, he said. The sights are used for a wide variety of weapons including M-16s and M-4 rifles, light M-249s machine guns, M-240 medium machine guns, heavy M2 machine guns and MK-19 grenade launchers.

Advancements in battery capacity and optics have resulted in smaller pixel sizes, which in turn reduces the size of the optics and lowers weight. New, small pieces of imaging equipment are becoming popular with special operations forces. Hand-held units, called XP-100 Thermal-eye, weigh about 13 minces and can be operated with a single switch. About 3,000 of these handheld units have been deployed to combat zones, according to Raytheon.