Challenge

 Our client needed to reduce the costs of their advanced helmet and display, whilst minimising weight and maintaining robustness.

Approach

Sagentia proposed a set of solutions to reduce the helmet’s cost whilst retaining the features most liked by pilots

• Novel processes, eg thixoforming metals for near net shape parts, resin transfer molding composites
• Devised complete system concepts
• Considered the through-life costs of the system, including manufacture, alignment, tailoring to pilots

Benefits

• The product now incorporates process improvements with system level proposals fed into the future product plan
• A cost reduction of 50% has been achieved without any adverse impact on ‘feel’ and robustness