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New experiments that target the B-mode polarization signals in the Cosmic Microwave Background require more sensitivity, more detectors, and thus larger-aperture millimeter-wavelength telescopes, than previous experiments. These larger apertures require ever larger vacuum windows to house cryogenic optics. Scaling up conventional vacuum windows, such as those made of High Density Polyethylene (HDPE), require a corresponding increase in the thickness of the window material to handle the extra force from the atmospheric pressure. Thicker windows cause more transmission loss at ambient temperatures, increasing optical loading and decreasing sensitivity. We have developed the use of woven High Modulus Polyethylene (HMPE), a material 100 times stronger than HDPE, to manufacture stronger, thinner windows using a pressurized hot lamination process. We discuss the development of a specialty autoclave for generating thin laminate vacuum windows and the optical and mechanical characterization of full scale science grade windows, with the goal of developing a new window suitable for BICEP Array cryostats and for future CMB applications. 

Observations of the Cosmic Microwave Background rely on cryogenic instrumentation with cold detectors, readout, and optics providing the low noise performance and instrumental stability required to make more sensitive measurements. It is therefore critical to optimize all aspects of the cryogenic design to achieve the necessary performance, with low temperature components and acceptable system cooling requirements. In particular, we will focus on our use of thermal filters and cold optics, which reduce the thermal load passed along to the cryogenic stages. To test their performance, we have made a series of in situ measurements while integrating the third receiver for the BICEP Array telescope. In addition to characterizing the behavior of this receiver, these measurements continue to refine the models that are being used to inform design choices being made for future instruments.