The HMD (Helmet Mounted Display) visor is a sophisticated article. It is both the optical combiner for the display and
personal protective equipment for the pilot. The visor must have dimensional and optical tolerances commensurate with
precision optics; and mechanical properties sufficient for a ballistic shield. Optimized processes and tooling are
necessary in order to manufacture a functional visor. This paper describes the manufacturing development of the visor
for the Joint Strike Fighter (JSF) HMD. The analytical and experimental basis for the tool and manufacturing process
development are described; as well as the metrological and testing methods to verify the visor design and function.
The requirements for the F-35 JSF visor are a generation beyond those for the HMD visor which currently flies on the
F-15, F-16 and F/A-18. The need for greater precision is manifest in the requirements for the tooling and molding
process for the visor. The visor is injection-molded optical polycarbonate, selected for its combination of optical,
mechanical and environmental properties. Proper design and manufacture of the tool - the mold - is essential. Design
of the manufacturing tooling is an iterative process between visor design, mold design, mechanical modeling and
polymer-flow modeling. Iterative design and manufacture enable the mold designer to define a polymer shrinkage
factor more precise than derived from modeling or recommended by the resin supplier.
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