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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. 

The BICEP/Keck series of experiments target the Cosmic Microwave Background at degree-scale resolution from the South Pole. Over the next few years, the "Stage-3" BICEP Array (BA) telescope will improve the program's frequency coverage and sensitivity to primordial B-mode polarization by an order of magnitude. The first receiver in the array, BA1, began observing at 30/40 GHz in early 2020. The next two receivers, BA2 and BA3, are currently being assembled and will map the southern sky at frequencies ranging from 95 GHz to 150 GHz. Common to all BA receivers is a refractive, on-axis, cryogenic optical design that focuses microwave radiation onto a focal plane populated with antenna-coupled bolometers. High-performance antireflective coatings up to 760 mm in aperture are needed for each element in the optical chain, and must withstand repeated thermal cycles down to 4 K. Here we present the design and fabrication of the 30/40 GHz anti-reflection coatings for the recently deployed BA1 receiver, then discuss laboratory measurements of their reflectance. We review the lamination method for these single- and dual-layer plastic coatings with indices matched to various polyethylene, nylon and alumina optics. We also describe ongoing efforts to optimize coatings for the next BA cryostats, which may inform technological choices for future Small-Aperture Telescopes of the CMB "Stage 4" experiment.