ARC Energy’s new, proprietary CHES 500 furnace has successfully produced the world’s largest crack-free sapphire crystal boule – for the second time.
Weighing in at 300 kg (660 lbs.), the cylindrical portion of the crystals measure 500mm in diameter and 340mm in height.
These sapphire boules are expected to meet manufacturing standards for the production of consumer products such as smartphone screens and cover glass, LED substrates, and large optical windows such as those used in lasers.
ARC Energy estimates that each boule could yield quantities up to 4,000 smartphone covers, up to 5,600mm of 4-inch LED wafers, or up to 2,500mm of 6-inch LED wafers.
Optical grade synthetic sapphire lenses have applications including IR laser beam steering, imaging and focusing optics or chemical and erosion-resistant optical surfaces.
“Growing 300-plus kilogram sapphire boules, largest in the world, is challenging. Showing repeatability is essential to gaining market confidence. With this repeat run using the same exact process, we have shown the stability of our process,” said Dr. Rick Schwerdtfeger, co-founder and CTO of ARC Energy.”
“With this automated and repeatable process, our technology is currently able to provide 70mm x 140mm sapphire mobile screen bricks for costs of around $8 per mm.”
Typical market cost is around $10-12 per mm, but with high yield manufacturing capabilities, future costs may be reduced as low as $5-6 per mm, facilitating long term plans for next generation products.
The boules pictured are “as-grown,” with no processing done after removal from the furnace. The slight discoloration is in a thin skin on the outside of the boule, which is not incorporated into the bricks during brick slicing.Dr. Schwerdtfeger with 300 kg sapphire boules repeated in CHES 500. (PRNewsFoto/Advanced RenewableEnergy Co. LLC)
“Our team has done a great job of developing a stable and repeatable process,” commented Dr. Kedar Gupta, CEO of ARC Energy. “We are excited about the future of this product, and to aid the industry in solving their challenges”.
The CHES 500 crystal growth furnace is fully automated, with a chamber that is currently the largest in the world.
ARC Energy has received its first purchase order for CHES 500 furnaces, with the first shipments scheduled for Q3 of this year. Discussions with several other companies for large production orders are underway.
For more information on ARC Energy’s CHES 500 furnace and sapphire boule production, visit their website.