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Proceedings Paper

Manufacturing development of visor for binocular helmet mounted display
Author(s): David Krevor; Timothy Edwards; Eric Larkin; John Skubon; Robert Speirs; Tom Sowden
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Paper Abstract

The HMD (Helmet Mounted Display) visor is a sophisticated article. It is both the optical combiner for the display and personal protective equipment for the pilot. The visor must have dimensional and optical tolerances commensurate with precision optics; and mechanical properties sufficient for a ballistic shield. Optimized processes and tooling are necessary in order to manufacture a functional visor. This paper describes the manufacturing development of the visor for the Joint Strike Fighter (JSF) HMD. The analytical and experimental basis for the tool and manufacturing process development are described; as well as the metrological and testing methods to verify the visor design and function. The requirements for the F-35 JSF visor are a generation beyond those for the HMD visor which currently flies on the F-15, F-16 and F/A-18. The need for greater precision is manifest in the requirements for the tooling and molding process for the visor. The visor is injection-molded optical polycarbonate, selected for its combination of optical, mechanical and environmental properties. Proper design and manufacture of the tool - the mold - is essential. Design of the manufacturing tooling is an iterative process between visor design, mold design, mechanical modeling and polymer-flow modeling. Iterative design and manufacture enable the mold designer to define a polymer shrinkage factor more precise than derived from modeling or recommended by the resin supplier.

Paper Details

Date Published: 18 September 2007
PDF: 9 pages
Proc. SPIE 6671, Optical Manufacturing and Testing VII, 667109 (18 September 2007); doi: 10.1117/12.732123
Show Author Affiliations
David Krevor, Rockwell Collins Display Systems (United States)
Timothy Edwards, Rockwell Collins Display Systems (United States)
Eric Larkin, Rockwell Collins Display Systems (United States)
John Skubon, MXL Industries (United States)
Robert Speirs, Ferris State Univ. (United States)
Tom Sowden, Contour Metrological and Manufacturing (United States)

Published in SPIE Proceedings Vol. 6671:
Optical Manufacturing and Testing VII
James H. Burge; Oliver W. Faehnle; Ray Williamson, Editor(s)

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