With Douglas Ball Inc. for Canadian Aviation Electronics

Using fiber optic technology, the computer sends images which are projected on two optic displays positioned just ahead of the pilots eyes.

The alignment of these displays is very critical and highly dependent upon proper helmet fit.
Critical requirements that had to be met were that the helmet shell would be lightweight but at the same time extremely rigid to be able to support the loads of the optic mounts.

Numerous attempts were made to develop an accurate component mixture suitable for rapid set up yet allowing for even distribution of foam throughout the entire liner.

The ‘foaming rig’, shown above, was developed to ensure the precise positioning of the mold to the pilots head. Polyurethane foaming agents were then poured into the molds and instantaneously set to the shape of the head.