Client Description
Rockwell Collins provides defense communications and defense electronic systems to the U.S. Department of Defense, Ministries of Defense throughout the world and manufacturers of military platforms. The product that MXL highlights in this solution profile is the Joint Helmet Mounted Cueing System (JHMCS), which provides first shot, high off-boresight weapons engagement capabilities. JHMCS enables pilots to direct weapons against enemy aircraft while performing high-G maneuvers and is also effective for accurately targeting enemies on the ground. The pilot simply needs to point his/her head toward the target and the weapons will be directed to the location where the pilot is looking. JHMCS can be found on aircraft such as F-15, F-16 and F/A-18 fighters.
The Challenge
With the obvious criticality of performance of this product, Rockwell Collins had to find a supplier that could reliably design and construct a plastic injection mold to the strict mechanical tolerances required in a military pilot helmet. They also needed an optical quality injection molder who could produce top-quality polycarbonate visors that would be hard coated to provide abrasion resistance, as well as chemical resistance. And finally these visors require reflective (beamsplitter) and anti-reflective coatings to precise specifications enabling proper operation of the helmet mounted "heads-up" display's vision systems.
The MXL Solution
Each step of this product is a very tall order, and being able to fulfill every aspect of this challenge is what makes MXL a true world leader in our field. Listed below is how MXL has met and continues to meet Rockwell Collins' and the U.S. Military's needs:
- Master mold builders designed and built the JHMCS mold to exacting specifications.
- Optical plastic injection molding experts process the clear and tint polycarbonate resins to produce a mechanically correct part.
- Coating engineers apply a precise thickness of a coating designed to provide the abrasion and chemical resistance specified by the customer.
- Vacuum deposition engineers and technicians deposit specially designed beamsplitter and anti-reflective coating using custom designed masking to ensure proper location.
- Threaded throughout all these manufacturing processes are our Quality Department's efforts to ensure performance to specification and product traceability.
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