Advanced Materials and Manufacturing, ASA(ALT), Phase I
Enhanced Impact Protection HGU-56P Aviator Helmet
Topic Objective
The objective of this SBIR grant is to enhance impact protection of the HGU-56P aviator helmet, which is already known as the most protective helicopter helmet ever made. Currently, the HGU-56P helmet retrofit of lining material is capable of delivering threshold impact performance improvement of 20% over current Extended Polystyrene (EPS) foam.
Description
At present, aviation helmets provide minimal impact protection due to weight limitations associated with crash load requirements. For example, if the helmet is too heavy under an otherwise survivable crash landing, the weight of the helmet cannot allow breaking the neck of the aviator. Optimal helmet design requires a balance between the need for protection from trauma and the comfort and practicality of the helmet for the user to ensure the best outcomes. New foam technology used in commercial industry promises superior crash protection with no impact on helmet weight. Improved impact protection to the user in a hard landing or crash scenario is a fundamental component of soldier lethality, one of the six army modernization priorities of the Army which includes the core requirement of communication.
Intent of this proposal is to perform retrofit using a new material/design which spreads out impact load and cuts the energy absorbed by the user to reduce instances of brain injury/Post-traumatic stress disorder (PTSD) and concussion. A redesign of the helmet will not be an option consideration due to cost reasons.
This solicitation intends to identify an existing commercial technology to provide the best overall reduction in impact energy to the user. Key considerations for evaluation shall at minimum (but not be limited to) include reduction in impact energy by comparison to EPS (threshold is 20%, objective is 40%), weight, cost of material, ability to absorb more than one impact without requiring replacement, and ability to retrofit a standard HGU-56P helmet without tools. Additional considerations shall be data showing user comfort is desired for proposed solution (ability of material to conform to user’s head to eliminate hot spots, material does not absorb sweat, heat (can the material vent heat from the user), etc.). Other factors may include material properties such as ability to perform under temperature ranges common to Army users and resistance to exposure to petroleum/oil/lubricants (POL) commonly encountered on Army helicopters.
Phase I
This effort shall identify and test the most promising material solution to reduce impact to the user, which can be retrofit into the HGU-56P aviator helmet with no weight gain to the helmet and at the least cost. The initial proposal shall identify a solution which provides impact energy reduction by comparison to EPS foam. Data showing attenuation of the technology proposed by comparison to EPS foam shall be included in the proposal. The contractor shall perform a laboratory demonstration in Phase I demonstrating and quantifying impact reduction in tests using two Government furnished HGU-56P helmets in the same size. The contractor shall modify one of the helmets with the proposed improvements and perform identical tests using one modified and one unmodified HGU-56P helmet so that comparison data clearly shows performance improvements achieved. Crash testing shall be done per the item specification for the HGU-56P helmet, in System 2 Helmet Configuration (AIHS-FS-0002), Section 4.2.5.2-4.2.5.3, titled Aircrew Integrated Helmet System Fabrication Specification. For cost reasons, testing shall only be done on the crown of the helmet. The final report shall estimate costs and weight impact of the technology solution proposed and document the actual impact energy absorption measured in the laboratory demonstration test.
Key meetings shall be a kickoff meeting within 3 weeks of contract award, bi-weekly telecons not to generally exceed 30 minutes in length with a single point of contact who can brief status of project and a test readiness review, which can be combined with a bi-weekly telecom. The contractor shall host Government witness of the laboratory demonstration, with particular focus on test setup.
Phase II
The solution identified in Phase I will be applied and tested to meet all requirements of the specifications proposed for update or replacement in all helmet sizes. The contractor shall propose changes for all lining material in the helmet being replaced. The contractor shall purchase helmets in all user sizes to support testing. Crash testing shall be done per the item specification for the HGU-56P helmet, AIHS-FS-0002, Section 4.2.5.2-4.2.5.3, titled Aircrew Integrated Helmet System Fabrication Specification for all helmet sizes retrofitted with new material solution. A summary report at the end of the test shall document performance improvement of the new solution. The contractor shall update the Aircrew Integrated Helmet System Fabrication Specification to reflect new performance capability of the new material. This may include the addition of testing for rotational energy reduction. The contractor shall perform analysis or test demonstrating performance does not change at high and low operating temperatures.
Deliverables will include a test plan, test report, an updated performance specification reflecting measured improvement in impact absorption energy performance, minutes for all meetings conducted with the vendor, presentation slides for test readiness review, a white paper detailing the installation cost of the retrofit solution, and a cost report detailing manufacturing cost as a function of helmet quantity from a minimum of 50 and up to 1000 at a time. The test report shall document all test results done under the contract. A retrofit procedure for replacing the existing helmet liners with the new solution shall be required and demonstrated at the end of the contract.
Key meetings shall be a kickoff meeting within 3 weeks of contract award, bi-weekly telecons not to generally exceed 30 minutes in length with a single point of contact who can brief status of project and a test readiness review, which can be combined with a bi-weekly telecom. The contractor shall host Government witness of any testing, with particular focus on test setup.
Phase III
Develop production processes for all materials necessary for retrofit into HGU-56P helmet in all user sizes. Update any specifications needed to reflect final production configuration weight and performance. Repeat bench qualification testing if production configuration deviates too far from prototype configuration tested in Phase II. Support operational testing on multiple Army rotary wing aircraft to evaluate user comfort. Aviation helmets used throughout DoD may find retrofit application for this same solution, not to mention the potential for helmets common to Army ground soldiers.
Submission Information
To submit full proposal packages, and for more information, visit the DSIP Portal.
References:
- https://newatlas.com/materials/liquid-nanofoam-football-helmet-head-protection/
- https://newatlas.com/materials/elastic-microlattice-helmet-padding/
- https://www.infrastructure.gov.au/roads/safety/publications/2001/helmet_liner.asp
- https://kaliprotectives.com/pages/the-future-of-protectives
- https://helmets.org/liners.htm
Topic Objective
The objective of this SBIR grant is to enhance impact protection of the HGU-56P aviator helmet, which is already known as the most protective helicopter helmet ever made. Currently, the HGU-56P helmet retrofit of lining material is capable of delivering threshold impact performance improvement of 20% over current Extended Polystyrene (EPS) foam.
Description
At present, aviation helmets provide minimal impact protection due to weight limitations associated with crash load requirements. For example, if the helmet is too heavy under an otherwise survivable crash landing, the weight of the helmet cannot allow breaking the neck of the aviator. Optimal helmet design requires a balance between the need for protection from trauma and the comfort and practicality of the helmet for the user to ensure the best outcomes. New foam technology used in commercial industry promises superior crash protection with no impact on helmet weight. Improved impact protection to the user in a hard landing or crash scenario is a fundamental component of soldier lethality, one of the six army modernization priorities of the Army which includes the core requirement of communication.
Intent of this proposal is to perform retrofit using a new material/design which spreads out impact load and cuts the energy absorbed by the user to reduce instances of brain injury/Post-traumatic stress disorder (PTSD) and concussion. A redesign of the helmet will not be an option consideration due to cost reasons.
This solicitation intends to identify an existing commercial technology to provide the best overall reduction in impact energy to the user. Key considerations for evaluation shall at minimum (but not be limited to) include reduction in impact energy by comparison to EPS (threshold is 20%, objective is 40%), weight, cost of material, ability to absorb more than one impact without requiring replacement, and ability to retrofit a standard HGU-56P helmet without tools. Additional considerations shall be data showing user comfort is desired for proposed solution (ability of material to conform to user’s head to eliminate hot spots, material does not absorb sweat, heat (can the material vent heat from the user), etc.). Other factors may include material properties such as ability to perform under temperature ranges common to Army users and resistance to exposure to petroleum/oil/lubricants (POL) commonly encountered on Army helicopters.
Phase I
This effort shall identify and test the most promising material solution to reduce impact to the user, which can be retrofit into the HGU-56P aviator helmet with no weight gain to the helmet and at the least cost. The initial proposal shall identify a solution which provides impact energy reduction by comparison to EPS foam. Data showing attenuation of the technology proposed by comparison to EPS foam shall be included in the proposal. The contractor shall perform a laboratory demonstration in Phase I demonstrating and quantifying impact reduction in tests using two Government furnished HGU-56P helmets in the same size. The contractor shall modify one of the helmets with the proposed improvements and perform identical tests using one modified and one unmodified HGU-56P helmet so that comparison data clearly shows performance improvements achieved. Crash testing shall be done per the item specification for the HGU-56P helmet, in System 2 Helmet Configuration (AIHS-FS-0002), Section 4.2.5.2-4.2.5.3, titled Aircrew Integrated Helmet System Fabrication Specification. For cost reasons, testing shall only be done on the crown of the helmet. The final report shall estimate costs and weight impact of the technology solution proposed and document the actual impact energy absorption measured in the laboratory demonstration test.
Key meetings shall be a kickoff meeting within 3 weeks of contract award, bi-weekly telecons not to generally exceed 30 minutes in length with a single point of contact who can brief status of project and a test readiness review, which can be combined with a bi-weekly telecom. The contractor shall host Government witness of the laboratory demonstration, with particular focus on test setup.
Phase II
The solution identified in Phase I will be applied and tested to meet all requirements of the specifications proposed for update or replacement in all helmet sizes. The contractor shall propose changes for all lining material in the helmet being replaced. The contractor shall purchase helmets in all user sizes to support testing. Crash testing shall be done per the item specification for the HGU-56P helmet, AIHS-FS-0002, Section 4.2.5.2-4.2.5.3, titled Aircrew Integrated Helmet System Fabrication Specification for all helmet sizes retrofitted with new material solution. A summary report at the end of the test shall document performance improvement of the new solution. The contractor shall update the Aircrew Integrated Helmet System Fabrication Specification to reflect new performance capability of the new material. This may include the addition of testing for rotational energy reduction. The contractor shall perform analysis or test demonstrating performance does not change at high and low operating temperatures.
Deliverables will include a test plan, test report, an updated performance specification reflecting measured improvement in impact absorption energy performance, minutes for all meetings conducted with the vendor, presentation slides for test readiness review, a white paper detailing the installation cost of the retrofit solution, and a cost report detailing manufacturing cost as a function of helmet quantity from a minimum of 50 and up to 1000 at a time. The test report shall document all test results done under the contract. A retrofit procedure for replacing the existing helmet liners with the new solution shall be required and demonstrated at the end of the contract.
Key meetings shall be a kickoff meeting within 3 weeks of contract award, bi-weekly telecons not to generally exceed 30 minutes in length with a single point of contact who can brief status of project and a test readiness review, which can be combined with a bi-weekly telecom. The contractor shall host Government witness of any testing, with particular focus on test setup.
Phase III
Develop production processes for all materials necessary for retrofit into HGU-56P helmet in all user sizes. Update any specifications needed to reflect final production configuration weight and performance. Repeat bench qualification testing if production configuration deviates too far from prototype configuration tested in Phase II. Support operational testing on multiple Army rotary wing aircraft to evaluate user comfort. Aviation helmets used throughout DoD may find retrofit application for this same solution, not to mention the potential for helmets common to Army ground soldiers.
Submission Information
To submit full proposal packages, and for more information, visit the DSIP Portal.
References:
- https://newatlas.com/materials/liquid-nanofoam-football-helmet-head-protection/
- https://newatlas.com/materials/elastic-microlattice-helmet-padding/
- https://www.infrastructure.gov.au/roads/safety/publications/2001/helmet_liner.asp
- https://kaliprotectives.com/pages/the-future-of-protectives
- https://helmets.org/liners.htm