Multiple Navy organizations have joined forces to bolster aircrew protection with a new application of additive manufacturing: a 3D printed version of the Joint Helmet Mounted Cueing System (JHMCS).
The effort involves 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), all working to modernize training for aircrew survival equipment roles.
“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.”
Tackling Cost and Logistics Barriers
The shift to 3D printing directly responds to longstanding issues tied to the traditional visor supply chain. The legacy JHMCS visor cost roughly $870 each and could take years to procure, constraints that slowed curriculum delivery and sustained operations. With CNATT anticipating a need for around 40 visors every year, the conventional acquisition approach was seen as both expensive and inefficient.
Aligned with service-wide goals to strengthen readiness and control spending, PMA-205 and Ready Relevant Learning (RRL)/A School staff explored fresh solutions to maintain training momentum and promote a safer aviation force.
The team settled on developing a prototype visor printed using Acrylonitrile Butadiene Styrene. The additively manufactured part satisfied core requirements, such as dimensional precision, compatibility with the Helmet Display Unit, and the same working characteristics maintainers expect when trimming components.
The result is a visor that can be produced within weeks rather than years and at approximately 65% less cost. The program also generated a technical data package so that units can reproduce the design independently, setting the stage for a broader, repeatable supply model. “This initiative represents more than just a cost reduction,” said Schiffelbein. “It is a proactive investment in agility, instructional fidelity and long-term readiness.”
Additive Manufacturing Expands Protective Gear Options
Defense agencies are increasingly turning to additive manufacturing to rethink personal protection. In 2021, General Lattice, a computational design company, was awarded a contract by the U.S. Army to improve the energy-absorbing performance of combat helmets. Working out of its Chicago headquarters, the firm spent one year developing a digital design and simulation framework capable of producing lattice structures outperforming conventional foams.
Leveraging computational modeling and additive manufacturing, the team produced helmet padding engineered to meet real-world impact scenarios and DEVCOM Soldier Center requirements. The printed lattices underwent performance and durability testing, with the objective of boosting soldier protection and survivability.
Elsewhere, the Defense Logistics Agency Troop Support’s Product Test Center has adopted 3D printing to make glove evaluations safer. Engineers created a printed mechanical hand that bends like a real one, enabling gloves to be checked for leaks without exposing staff to hazardous chemicals such as jet fuel. The project originated from a request to test gloves used by fuel handlers. Previously, evaluators had to wear the gloves and manually flex their hands in fuel, risking chemical exposure if the glove failed. General engineer Edward Dalton proposed the 3D printed surrogate hand, preserving test accuracy while eliminating danger to personnel.
The 3D Printing Industry Awards are back. Make your nominations now.
Do you operate a 3D printing start-up? Reach readers, potential investors, and customers with the 3D Printing Industry Start-up of Year competition.
To stay up to date with the latest 3D printing news, don’t forget to subscribe to the 3D Printing Industry newsletter or follow us on Linkedin.
Featured image shows Sailors equipped with cutting-edge 3D printed Joint Helmet Mounted Cueing System. Photo via Navy.
