I'd be happy for you to do that. It seems good to me that someone makes a record of the manufacturing processes we had. In fact, I'd like to give a longer description of the facility, what I can remember of it, 22 years after the fact. Feel free to use what you like.
Laser assembly took place in the Optical Systems Division building, located on Walnut Street in Garland, on the other side of a small road from a Long John Silvers. Google Maps shows it was near 2203 W Walnut St, Garland, TX 75042. The LJS apparently is gone, and the entire laser facility is just a grassy field and parking lot behind Baylor Hospital. Even the little road is gone, though you can still see vestiges of it if you know where to look. The laser facility was a rectangular, concrete, single-story building. I was fascinated by the parking lot lamps, which had large, clear glass spheres on top of round, black poles; the way they were arranged on the property was hypnotic to me. Behind the building were tall metal pipes painted matte black. I remember that one of them had a large, circular hole near the top. When I asked about them, I was told these were used for testing laser beam propagation.
The building had one entrance on the short side facing Walnut Lane, and a side entrance way down at the far end of the building on the left side of the building. I usually entered through the entrance on the left side of the building. It was a badged entry. After swiping my badge on the sensor, I would enter and greet the secretary seated at a small desk in the alcove. She might have had Parkinson's, as she always shook, and she walked with difficulty using a walker.
I walked down a hallway and around a corner to another hallway. I could see electronics assembly work stations through the half-glass walls along the hall. Somewhere along the way, I put on a hairnet, smock and booties. Then, I came to a sliding door through which I passed into a vestibule. This was the airlock used to maintain our Type 10 clean room. Laser assembly took place inside the clean room. To the left was the assembly process for the Cr:Er:glass eye-safe laser range finder; to the right was the assembly process for a non-eye safe IR laser range finder used on missiles. I worked on the left side.
As clean as the room was, we used flow hoods at each work station to provide an even cleaner assembly environment. We did our work while wearing finger cots, latex that fit over our fingers. We had to change them every twenty or thirty minutes, as our skin oils and sweat would otherwise penetrate the latex sufficiently to contaminate our work surfaces. We worked ten to sixteen-hour shifts, with a half-hour lunch break and short breaks during the day.
My understanding is that the Cr:Er:glass laser range finder was supposed to function similar to a pair of binoculars. A user would hold it up to his eye like a pair of binoculars, to sight a target. Once sighted, the user could push a button to emit a laser pulse that would reflect off the target, and the trip time measured by the unit. I never actually saw this finished device in real life, but I remember seeing photos of them.
After entering the clean room from the airlock, I faced the solid metal backs of some work stations, reaching up nearly to my shoulders, so I could see across the room. I walked to my left to the end of the row of three work stations side-by-side, and then made a u-turn to my right. My work station with flow hood was straight ahead of me, with one work station to the left of mine. To the left of that work station was a wall. In front of the wall was a stand that had plastic tubs containing the raw parts that we assembled, flash lamps and little square plastic boxes with flip-top lids and foam rubber inserts holding the laser rods. Each flash lamp cost something like $50, and each laser rod cost somewhere around $600 or $800. I don't remember what the gold-plated reflectors cost.
We cleaned the ends of each laser rod prior to assembling into a laser cavity. We had little plastic squirt bottles that held our solvents. I think we also had distilled water. We had a specific sequence of solvents we were to use, but I don’t remember what it was. Each lens tissue could make only a single pass across a laser rod. So, we would put the dry lens tissue on top of the rod end, apply a drop of solvent, then drag the tissue across the rod end, and then throw the tissue away. We did that for each of the three solvents, and then examined the rod under magnification for cleanliness.
We also examined the ends of each rod under magnification to check the quality of the antireflective optic coating. The coating lab had production problems, resulting in tiny bubbles or dust in the coating. The bubbles shone like little stars. We had to reject the rods if they had too many imperfections in the coatings. As I mentioned, we also checked the chamfer of the ends. If we rejected a rod, we put it back in the little box and put the box into a tub of rejects. The coating lab was working on salvaging some of the rods, though without much success. Actually, the results were horrible, and I rejected every one of those refurbs that I saw.
I accidentally snapped a laser rod while assembling a laser cavity. It was a stupid mistake; I adjusted the height of the rod while it was in the gig, instead of disassembling the whole thing, and the rod snapped under stress when it began bending over a piece of metal attached to the gig. I quietly put the rod in a box and placed it in the reject bin. I was relieved that no one ever said anything about it.
As a joke, one of my co-workers put a small pieces of paper folded up into one of the boxes, with a note on it saying, “Help, I’m trapped and forced to build lasers.”
I put the o-rings on the laser rod while under magnification, too. I remember that the rubber o-rings were naturally filthy, at least from our magnified, highly-clean perspective. Rubber has natural oils in it, and has a flaky surface, either of which would contaminate the ends of the laser rod and our finger cots. We had to change finger cots after putting the rubber o-rings on the laser rod, and we had to be careful not to touch the end of the rod with the rubber o-ring.
As I walked around the room, I might pass the man whose job was measuring the room’s air quality. He had an instrument on a wheeled stand that told him how many particles of dust were in the air. He rolled this device around the entire clean room to make his tests.
On the left side of the room was a window for passing small items between the lab on the other side of the wall with our lab. A little farther down our room on that side was the optic alignment check room. Across from that room was the station where the firing circuits were added to the laser cavity. Somewhere along here, the laser cavity was removed from the gig and placed on its permanent mount.
I don’t remember which stations came after the firing circuits, but down at the far end of the room was the QC Department, which checked all our work. One of my classmates from Albuquerque Technical-Vocational Institute, where we both graduated with AAS degrees in Laser Electro-Optic Technology, worked in the QC Department. I never knew why management chose to put him in QC and me assembling laser cavities. I think we both were working on the eye-safe laser range finder because it was considered easier to assemble than the laser system for the missiles; experienced laser techs went over to that side.
Environmental testing took place in a completely different room in a different part of the building. I never saw it. Other rooms in the building included a room with a sandblaster and a grinder. I remember that someone helped me retrofit a broken hex wrench so I could do my job; it was sometimes difficult to find the tools we needed to assemble lasers.
I think it was before Christmas that I found that the electronics assembly rooms were unmanned and the lights turned off. Management had also brought in temp workers to help us assemble lasers, but then it turned out that the laser techs (who had laser degrees and were full-time employees with benefits) were being replaced by the temp workers. One of the temp workers was so disgusted by what management was doing to us that he quit in protest. Even so, we didn’t know when our end was arriving. For me, it was January 13, I think, when I was hunched over my workbench, getting everything set up to begin work, when my supervisor told me to follow him. We walked to the other side of the room, the missile side, and he told one of the workers on that side to join us. We were told to meet in a room on a certain day and time. As I said, there were about 200 of us in there. I saw the woman who walked with the walker in there with us, too.