18 September 2007 Manufacturing development of visor for binocular helmet mounted display
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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.
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David Krevor, David Krevor, Timothy Edwards, Timothy Edwards, Eric Larkin, Eric Larkin, John Skubon, John Skubon, Robert Speirs, Robert Speirs, Tom Sowden, Tom Sowden, } "Manufacturing development of visor for binocular helmet mounted display", Proc. SPIE 6671, Optical Manufacturing and Testing VII, 667109 (18 September 2007); doi: 10.1117/12.732123; https://doi.org/10.1117/12.732123

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