Abstract
This paper summarises work undertaken on the design, manufacturing development, and impact testing of a lightweight composite aircrew helmet. Full details are given on the double diaphragm forming process, developed at DERA, which has been extensively used to manufacture the complex, doubly curved layers that form the final helmet assembly. Manufacturing options for the development of a ‘form fitting’ foam liner are also included, as are developments in the foam liner press moulding processes.
Results from an extensive impact test programme conducted on fully assembled shell samples are provided, illustrating good energy management during test. Some redundant material was apparent from the results, hence further mass reduction is possible. Modification of the layer deformation sequence is also required. However the sandwich shells met all impact test requirements. Correlation of the impact test data and helmet damage cross- sections has allowed recommendations to be made regarding improved design and manufacture of the layered construction. Predictions based on these improvements show the final helmet mass should be ∼750 g, excluding breathing systems and communications.
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