LA NPDT — LA New Product Development Team

Our work / Customized Insert for Air Force Fighter Pilot Helmets:

Reducing Neck Pain by Addressing Helmet Weight Balance

Neck pain caused by the forward shift in the center of gravity in advanced helmets.

  • Product Design and Development
  • Prototyping
  • 3D Printing
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Reducing Neck Pain by Addressing Helmet Weight Balance

Project snapshot

A customized 3D-printed insert for pilot helmets. It eases neck pain caused by the forward weight shift of the latest heads-up display helmets.

The LA New Product Development Team delivered Reducing Neck Pain by Addressing Helmet Weight Balance, covering product design and development, prototyping and 3d printing. The work sits in our sports & fitness experience, where we take an idea from concept through design, prototyping and manufacturing readiness.

Services applied
Product Design and Development, Prototyping and 3D Printing
Project type
Customized Insert for Air Force Fighter Pilot Helmets:
Our product development team at LA NPDT tackled a critical issue affecting pilots:
With modern helmets incorporating numerous features and devices, the added weight at the front increases pressure and strain on pilots’ necks, leading to chronic pain and discomfort. Our innovative solution provides a simple yet effective method to mitigate this problem, ensuring pilots can perform their duties with reduced pain and increased comfort.
Advancements in helmet design have led to increased weight and a forward-shifted center of gravity, exacerbating neck pain among both air force fighter pilots and helicopter pilots.
This issue jeopardizes mission success and reduces force readiness, as pilots may avoid flying to their full potential to lessen their pain.
Previous attempts at solving this issue failed due to the added bulk and restriction of head movements by external devices.

Previous Efforts and Our Differentiation

Canada’s Defense Research and Development developed novel Neck Support Systems (NECSUS) for helicopter pilots wearing Helmet Mounted Systems (HMS) during Search and Rescue (S&R) missions.
during Search and Rescue (S&R) missions.
These systems include the Bracing Collar Concept (BCC), Hooded Collar Vest (HCV), and Helmet Attachment Concept (HAC).
However, these devices, while providing considerable support, often transferred loads from the neck to the shoulders, torso, or back, restricting head movement and rendering them unsuitable for pilots.
Portfolio pilothelmet
Our solution is a customized 3D-printed insert designed to shift the center of gravity of pilot helmets backwards, aligning it with the pilot’s neck and spine.
This alignment significantly reduces the strain and pressure on the neck, alleviating chronic pain and discomfort caused by advanced helmet systems.
The insert is integrated into a balaclava, ensuring a seamless fit and effective weight distribution. Remarkably, the cost of the 3D-printed piece is typically less than $10, making it an incredibly cost-effective solution.

Here's how our solution works

  1. Customized Fit
    01

    Customized Fit

    We begin by scanning the pilot’s head to create a 3D model tailored to the exact shape of their skull. This ensures the insert fits perfectly, taking into account the unique anatomy of each pilot.
  2. 3D Printing
    02

    3D Printing

    Using the 3D model, we print a flexible yet supportive insert. This insert is specifically designed to shift the helmet’s center of gravity backwards, aligning it with the pilot’s neck and spine, thereby reducing strain and pressure. The cost of producing each 3D-printed insert is typically less than $10.
  3. Balaclava Integration
    03

    Balaclava Integration

    The insert is integrated into a balaclava, which is worn under the helmet. This integration ensures that the insert stays securely in place, providing consistent support and distributing the weight evenly across the head and neck.
  4. 04

    Simple Implementation

    The balaclava with the insert is easy to wear and adjust, allowing pilots to quickly don it before missions. The flexibility of the 3D-printed material ensures comfort and does not impede head movement or operational range of motion.
  5. Adaptability for Future Helmets
    05

    Adaptability for Future Helmets

    As helmet designs evolve, our solution can be quickly adapted. New inserts can be 3D printed to match updated helmet specifications, ensuring ongoing relevance and effectiveness in mitigating neck pain.

    By offering a tailored and cost-effective solution , we provide pilots with enhanced comfort and performance, ensuring they can operate at their best without the burden of neck pain.

Our solution was developed in response to an SBIR request from the Department of Defense.
Within just one week, we moved from concept to a practical and implementable design, showcasing our team’s ability to rapidly innovate and address urgent needs.
Significant Reduction in Neck Pain: Our insert has the potential to significantly reduce neck pain for pilots, improving their operational capabilities and overall comfort.
Thousands of Pilots Will Benefit: With widespread adoption, our solution could benefit thousands of pilots, enhancing their daily lives and mission performance.
Portfolio pilothelmet
As helmet development continues to incorporate additional devices and features, the issue of weight balance will only become more severe. Our simple and adaptable solution remains relevant, providing an effective method to mitigate this growing problem.
By offering a tailored and cost-effective solution, we aim to make a substantial impact on the well-being and efficiency of pilots worldwide, ultimately contributing to greater mission success and reduced medical treatment costs.

Key Skills and Services Utilized by LA New Product Development Team

Cross-Functional Expertise: Our team of engineers, prototyping experts, and manufacturing specialists collaborated seamlessly to develop a solution that addresses the specific needs of pilots.

Rapid Prototyping: Leveraging advanced 3D scanning and printing technologies, we were able to create a customized, functional prototype quickly and efficiently.

User-Centered Design: By focusing on the unique anatomy and needs of each pilot, we ensured our solution was both effective and comfortable, enhancing user experience.

Why Choose LA NPDT

Innovation and Agility: Our ability to move swiftly from concept to prototype within a week demonstrates our capacity for rapid innovation and problem-solving.

Cost-Effective Solutions: We designed an inexpensive solution, with a total cost under $50, making it accessible for widespread implementation.

Enhanced Performance and Well-Being: Our insert significantly reduces neck pain and discomfort for pilots, improving their performance and overall well-being.

At LA NPDT, we pride ourselves on our ability to deliver impactful, user-focused solutions.
Thanks to our expertise and dedication, pilots worldwide can now experience reduced neck pain, leading to better performance and overall health.
This project exemplifies our commitment to addressing real-world challenges with practical, effective innovations.
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Capabilities used on this project

  • Rapid prototyping services

    3D printing, CNC machining, urethane casting and functional prototype builds with published materials, tolerances and lead times.

  • Low-volume manufacturing

    Bridge tooling, short-run production and supplier management for first commercial batches.

Industries this project belongs to

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