Atomic
Layer Deposition (ALD) is very attractive for producing
optical quality thin films, including transparent barrier films on
metal-coated astronomical mirrors. To date, ALD of mirror coatings
has been limited to relatively small-sized substrates. A new ALD tool
has been designed, constructed, and tested to apply uniform protective
coatings over a 0.9 m diameter substrate in a 1 m diameter scale deposition
plane. The new tool, which we have named the meter scale ALD system
(MSAS), employs a unique chamber design that isolates a large substrate
surface to be coated by utilizing the substrate as a wall of the reaction
chamber. The MSAS is mechanically designed to be rapidly reconfigurable
for selective area coating of custom substrates with arbitrary shape,
size, and permanent backside hardware attachments. The design, implementation,
results, and future applications of this new tool are discussed for
coating large-area optical substrates, specifically protective coatings
for silver mirrors, and other future large astronomical optics. To
demonstrate the potential of this new design, aluminum oxide was deposited
by thermal ALD using trimethylaluminum and water at a low reaction
temperature of 60 °C. Growth rate and uniformity, which are dependent
on precursor pulse times and chamber purge times, show that the two
half-reactions occur in a saturated regime, matching typical characteristics
of ideal ALD behavior. Aluminum oxide deposition process parameters
of the MSAS are compared with those of a conventional 100 mm wafer-scale
ALD tool, and saturated ALD growth over the 0.9 m substrate is realized
with a simple scaling factor applied to precursor pulse and purge
times. This initial test shows that lateral thickness uniformity across
a 0.9 m substrate is within 2.5% of the average film thickness, and
simple steps to realize 1% uniformity have been identified for next
growths. Results show promising application of transparent robust
dielectric films as uniform coatings across large optical components
scaled to meter-sized substrates.