Cost optimisation of pilot helmet system

Over 50% cost reduction in production of helmet system.


 Our client needed to reduce the costs of their advanced helmet and display, whilst minimising weight and maintaining robustness.



Sagentia proposed a set of solutions to reduce the helmet’s cost whilst retaining the features most liked by pilots

  • Novel processes, eg thixoforming metals for near net shape parts, resin transfer molding composites
  • Devised complete system concepts
  • Considered the through-life costs of the system, including manufacture, alignment, tailoring to pilots



  • The product now incorporates process improvements with system level proposals fed into the future product plan
  • A cost reduction of 50% has been achieved without any adverse impact on ‘feel’ and robustness

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