U.S. Navy Prints Helmet Visors to Save Costs
The U.S. Navy has integrated additive manufacturing into its supply chain to produce critical components, such as flight helmet visors. This strategic shift allows for a 65% reduction in unit cost compared to traditional methods, transforming how the fleet is supplied. 🛠️
Replacing Injection Molding
The conventional injection molding process requires very expensive tools and molds, making it uneconomical to produce parts in small batches. By opting to 3D print these visors, the Navy eliminates that initial tooling expense, can manufacture only what's needed, and drastically accelerates the time to obtain the parts.
Key advantages of 3D printing:- 65% cost savings per unit by avoiding expensive molds.
- On-demand manufacturing in small batches without relying on external suppliers.
- Reduce delivery times from several weeks to just a few days.
The ability to manufacture locally provides greater logistical autonomy and is a strategic tool for keeping the fleet operational.
Technical Implementation and Material
The team at the Naval Air Station Jacksonville uses fused filament fabrication (FFF) 3D printers to create the visors. They use a specialized polymer that meets the rigorous standards of naval aviation: it must offer impact resistance and perfect optical clarity.
Validation process and future:- Exhaustive tests verify that the visor protects the pilot and does not distort their vision.
- The success of this project opens the door to using this technology for other critical equipment parts.
- Several batches have already been produced and distributed successfully to the squadrons that need them.
A Logistical Paradigm Shift
This case demonstrates how 3D printing is consolidating beyond prototyping, becoming a method of