The Simons Observatory: Production-Level Fabrication of the Mid- and Ultra-High-Frequency Wafers

The Simons Observatory (SO) is a cosmic microwave background instrumentation suite in the Atacama Desert of Chile. More than 65,000 polarization-sensitive transition-edge sensor (TES) bolometers will be fielded in the frequency range spanning 27 to 280 GHz, with three separate dichroic designs. The mid-frequency 90/150 GHz and ultra-high-frequency 220/280 GHz detector arrays, fabricated at NIST, account for 39 of 49 total detector modules and implement the feedhorn-fed orthomode transducer-coupled TES bolometer architecture. A robust production-level fabrication framework for these detector arrays and the monolithic DC/RF routing wafers has been developed, which includes single device prototyping, process monitoring techniques, in-process metrology, and cryogenic measurements of critical film properties. Application of this framework has resulted in timely delivery of nearly 100 total superconducting focal plane components to SO with 88% of detector wafers meeting nominal criteria for integration into a detector module: a channel yield >95% and T_c in the targeted range.