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A study investigating the physical properties and use of the SiAl composite Controlled Expansion 7 (CE7) for the packaging of silicon bolometric detectors for millimeter-wave astrophysical applications at cryogenic temperatures is presented. The existing interfaces to such detectors are typically made of either ductile metals or micro-machined silicon. As a composite of Si and Al, we find that CE7 exhibits properties of both in ways that may be advantageous for this application. This exploration of the physical properties of CE7 reveals: (a) superconductivity below a critical transition temperature, T c ∼ 1.2 K; (b) a thermal contraction profile much closer to Si than metal substrates; (c) the relatively low thermal conductivity anticipated for a superconductor, which can be improved by Au-plating; and (d) the feasibility of machining mechanical features with tolerances of ∼25 µm. We further discuss the use of CE7 in the cosmology large angular scale surveyor telescope array, which deployed CE7 in several of its detector focal planes.

Measuring the faint polarization signal of the cosmic microwave background (CMB) not only requires high optical throughput and instrument sensitivity but also control over systematic effects. Polarimetric cameras or receivers used in this setting often employ dielectric vacuum windows, filters, or lenses to appropriately prepare light for detection by cooled sensor arrays. These elements in the optical chain are typically designed to minimize reflective losses and hence improve sensitivity while minimizing potential imaging artifacts such as glint and ghosting. The Primordial Inflation Polarization ExploreR (PIPER) is a balloon-borne instrument designed to measure the polarization of the CMB radiation at the largest angular scales and characterize astrophysical dust foregrounds. PIPER's twin telescopes and detector systems are submerged in an open-aperture liquid helium bucket dewar. A fused-silica window anti-reflection (AR) coated with polytetrafluoroethylene is installed on the vacuum cryostat that houses the cryogenic detector arrays. Light passes from the skyward portions of the telescope to the detector arrays through this window, which utilizes an indium seal to prevent superfluid helium leaks into the vacuum cryostat volume. The AR coating implemented reduces reflections from each interface to <1% compared to ∼10% from an uncoated window surface. The AR coating procedure and room temperature optical measurements of the window are presented. The indium vacuum sealing process is also described in detail, and test results characterizing its integrity to superfluid helium leaks are provided.

We present the design, manufacturing technique, and characterization of a 3D-printed broadband graded index millimeter wave absorber. The absorber is additively manufactured using a fused filament fabrication 3D printer out of a carbon-loaded high impact polystyrene filament and is designed using a space-filling curve to optimize manufacturability using the said process. The absorber's reflectivity is measured from 63 GHz to 115 GHz and from 140 GHz to 215 GHz and is compared to electromagnetic simulations. The intended application is for terminating stray light in cosmic microwave background telescopes, and the absorber has been shown to survive cryogenic thermal cycling.

The dielectric properties of selected conductively-loaded polyimide samples are characterized in the microwave through far-infrared wavebands. These materials, belonging to the Vespel family, are more readily formed by direct machining than their ceramic-loaded epoxy counterparts and present an interesting solution for realizing absorptive optical control structures. Measurements spanning a spectral range from 1 to 600  cm -1 (0.03-18 THz) were performed and used in parametrization of the media's dielectric function at frequencies below ≈3  THz.

Strategies are explored to reduce the electromagnetic simulation time of electrically large superconducting transmission line structures while retaining model accuracy. The complex surface reactance of an infinite thin-film superconducting sheet is evaluated with the BCS (Bardeen-Cooper-Schrieffer) theory and used as an input to model the phase velocity and characteristic impedance of finite width transmission line structures. Commercially available electromagnetic simulation software are employed for the calculations and the results are compared with limiting analytic forms from the literature. The influences of line width, metallization thickness, and substrate height on microstrip transmission line propagation are considered in detail and a scaling approach is presented to compensate for the leading order effect in numerical simulations. These findings are particularly important near the energy gap of the superconductor due to the influence of the kinetic inductance on the transmission line dispersion.

We describe the design, fabrication, and validation of a cryogenically compatible quasioptical thermal source for characterization of detector arrays. The source is constructed using a graphite-loaded epoxy mixture that is molded into a tiled pyramidal structure. The mold is fabricated using a hardened steel template produced via a wire electron discharge machining process. The absorptive mixture is bonded to a copper backplate enabling thermalization of the entire structure and measurement of the source temperature. Measurements indicate that the reflectance of the source is <0.001 across a spectral band extending from 75 to 330 GHz.