Battelle produces high-performance metallic mesh coatings that provide excellent electromagnetic interference (EMI) shielding while maintaining high visible light and infrared transmission. They have over 25 years of experience designing, fabricating, and testing these coatings on various substrates. Their coatings can be applied to flat windows, curved domes, or flexible films in different shapes and sizes. Battelle has the capabilities to take projects from initial design through high-volume production and testing in their certified laboratories. They have worked with military and aerospace clients on projects including mesh coatings for the F-35 Joint Strike Fighter windows and Javelin missile domes.

1. High-Performance Patterned Metallic
Mesh Coatings
800.201.2011 ú solutions@battelle.org ú www.battelle.org
Boost Performance for EMI Shielding,
Thermal Management, or RCS Control
For large flat windows, curved dome surfaces, or
thin flexible films, Battelle is in a unique position to
lithographically apply micron-sized mesh coatings
that meet or exceed your requirements. By reducing
metal linewidths and features to micron dimensions,
Battelle’s mesh coatings provide the highest levels of
EMI shielding or heating while maintaining very high
visible and IR transmission. Twenty-five years of solid
technical experience combined with the facilities and
versatility to design, fabricate, manufacture, and test
a wide variety of coatings on any substrate enable
Battelle to deliver better performance at a cost-
effective price.
Flexibility and Quality
Battelle provides research and manufacturing from
proof of concept to volume production:
Whatever the material:
æ Visible: ZKN-7, BK-7, polyimide film, Mylar® film,
tempered glass, quartz, acrylic, fiber glass, and
polycarbonate
æ Infrared: ZnS, ZnSe, sapphire, germanium,
Tuftran™, Cleartran™, silicon, AlON, CaF2, and MgF.
Virtually any shape and size:
æ Flat windows up to 4 feet by 2 feet
æ Domes from 2-inch up to 9-inch diameters
æ Flexible sheets up to 2 feet by 10 feet
æ Complex curved surfaces
Our quality assurance capabilities are extensive and
include testing for:
æ RF and microwave attenuation
æ Visible and IR transmittance
æ Resistivity
æ Environmental resistance to humidity, temperature,
adhesion
One Stop—From Design to
Manufacturing and Testing
Battelle does it all, conducts research, prototyping,
limited- and high-volume production. We use
proprietary computer models that predict the
performance of metal mesh coatings on IR
transmitting windows and domes to fit design to your
needs. Battelle can modify our mesh parameters
to trade off shielding versus transmission, while
minimizing unwanted diffraction effects. We operate
two class 100 cleanrooms (totaling 7,000 square
feet), staffed by 20 cleanroom technicians, working
two shifts of operation.

2. 800.201.2011 ú solutions@battelle.org ú www.battelle.org
Battelle is the world’s largest independent research and development organization, providing innovative solutions to the world’s most pressing needs
through its global businesses: Laboratory Management, National Security, and Energy, Health and Environment. It advances scientific discovery and
application by conducting $6.5 billion in global R&D annually through contract research, laboratory management and technology commercialization.
Our world-class lithographic and metallization
capabilities enable us to fabricate metallic patterns
with micron-sized features over large and curved
optics. We are equipped to test for EMI shielding, IR
transmission, resistivity, environmental compliance,
and other critical performance requirements in our
ISO 9001:2008 certified laboratories. Keeping the
research and development team close to the product
means we solve problems quickly, accurately, and
cost effectively.
Experience Counts
Our clients include the Army, Navy, Air Force,
large aerospace contractors, and IR window
manufacturers. A partial listing of the projects Battelle
has conducted for these clients includes:
æ F-35 Joint Strike Fighter (JSF) Windows – Battelle
is currently in production on multiple windows for
the JSF.
æ Large area ZnS Windows—Battelle has applied
metallic mesh coatings to multiple large ZnS
windows, some as large as 30-inches by
30-inches, for various programs. Battelle
fabricated and delivered 30 sets of mesh-coated
windows.
æ Visible/IR Pod—Battelle designed, fabricated,
and tested a randomized mesh for use as a
combination EMI shield and defogging heater.
Battelle applied the EMI/heater meshes to over
100 sets of large germanium FLIR windows and
two ZKN-7 windows for use on a reconnaissance/
targeting pod.
æ Javelin Missile Dome—Battelle designed and
applied metallic mesh coatings to over 8000 ZnS
Javelin missile domes for the U.S. Army.
æ Resonant Mesh on Missile Domes—Battelle
developed a novel holographic interference
technique for fabricating short-wave IR bandpass
resonant mesh filters for the U.S. Army Missile
Command.
Our world-class lithographic and metalization capabilities
enable us to fabricate metallic patterns with feature sizes
approaching one micron over large and curved optics. We
are equipped to test for EMI shielding, IR transmission,
resistivity, environmental compliance, and other critical
performance requirements in our ISO 9001:2000 certified
laboratories. Keeping the research and development team
close to the product means we solve problems quickly,
accurately, and cost effectively.
Experience Counts
Our clients include the Army, Navy, Air Force, large
aerospace contractors, and IR window manufacturers. A
partial listing of the projects Battelle has conducted for these
clients includes:
– F/A-18 RECCE Windows—Battelle applied metallic mesh
coatings to large (11 inches by 14 inches) Tuftran™
infrared windows, extending a break-free mesh coating to
the edge of each window. Battelle fabricated and
delivered 30 sets of mesh-coated windows.
– Visible/IR Pod—Battelle designed, fabricated, and tes
a randomized mesh for use as a combination EMI shi
and defogging heater. Battelle applied the EMI/heater
meshes to over 100 sets of large germanium FLIR wind
and two ZKN-7 windows for use on a reconnaissance
targeting pod.
– Javelin Missile Dome—Battelle designed and is curre
delivering the mesh coating on high-volume productio
quantities of ZnS Javelin missile domes for the U.S. Ar
– Resonant Mesh on Missile Domes—Battelle develop
a novel holographic interference technique for fabrica
short-wave IR bandpass resonant mesh filters for the U
Army Missile Command.
800.201.2011 www.battelle.org/sub_pages/meshc.aspx solutions@battell
Battelle’s metallic mesh coatings provide the highest levels of
EMI protection and transparency.