A collaborative effort between several US Navy commands has seen the development of a 3D printed Joint Helmet Mounted Cueing System (JHMCS).
The Naval Aviation Training Systems and Ranges Program Office (PMA-205), Naval Education and Training Command (NETC), Center for Naval Aviation Technical Training (CNATT), and Commander, Naval Air Forces training and readiness (CNAF N7) are in the process of deploying additive manufacturing to 'support aircrew survival equipmentman rating training requirements.'
They consider the 3D printed JHMCS as a 'breakthrough in aircrew safety' and are said to have enhanced readiness and reduced lifecycle costs. The legacy JHMCS visor, with a unit cost of 870 USD and multi-year procurement timelines, posed delays to curriculum execution and fleet sustainment. Since the CNATT's projected annual requirement was in the region of 40 units, the existing supply model presented 'significant fiscal and operational limitations.'
Using 3D printing, the team developed a prototype visor made with ABS that met essential design criteria, including dimensional accuracy, smooth Helmet Display Unit integration, and familiar trimming characteristics. The new visors can now be produced with 65 per cent cost savings and in a compressed delivery timeline of weeks rather than years. The creation of a supporting technical data package has ensured replicability across fleet intermediate-level maintenance print sites, delivering what the naval commands believe to be a scalable and sustainable supply solution.
“This effort is a prime example of how collaboration and innovation across commands can deliver real results for the fleet,” said Capt. Jonathan Schiffelbein, PMA-205 program manager. “By leveraging additive manufacturing, our teams not only met critical training requirements but also advanced readiness and cut lifecycle costs, directly supporting our Sailors and the mission.
“This initiative represents more than just a cost reduction. It is a proactive investment in agility, instructional fidelity and long-term readiness.”
CNATT commander Capt. Michael Polito added: “This project is the epitome of what happens when we collaborate to provide aviation technical training solutions that will ultimately lead to positive outcomes in the fleet.”
