Attachment 1 - Test Plan_Redacted.pdf

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Table of Contents

1. INTRODUCTION

1.1 PURPOSE

1.2 SCOPE

1.3 KEY PERSONNEL

1.4 REFERENCES

1.5 DOCUMENT MAINTENANCE

1.6 TEST STRATEGY AND METHOD

1.7 SYSTEM TESTING

1.8 CONFIGURATION AND PROCEDURAL DETAILS

1.9 EQUIPMENT LIST

2. EVALUATION CRITERIA

3. TEST SCHEDULE

4. TEST SUMMARY REPORT

NGFWH

Aircrew Performance Branch

Windblast Test Plan 29 September 2025< Date of Document >

1. INTRODUCTION

The Next Generation Fixed Wing Helmet (NGFWH) system is a single helmet system that meets all fixed-wing mission requirements. The NGFWH system will replace the HGU-55/P and HGU-55A/P helmets and will provide a platform for future upgrades to the Hybrid Optical-based Inertial Tracker (HObIT) systems, the Joint Helmet Mounted Cueing System (JHMCS), and Digital Eye Piece (DEP) included with 4949 Night Vision Goggle (NVG). The NGFWH system integrates with existing and planned aircraft and Aircrew Flight Equipment (AFE) used by the Air Force.

The NGFWH system is critical to normal flight operations and emergency egress procedures. The NGFWH system shall be capable of withstanding ejection speeds up to 600 Knots Equivalent Air Speed (KEAS) while mitigating the likelihood of injury to the head and neck of the pilot. Additionally, it will provide protection and maintain the maneuverability of a pilot’s head in a high “G” environment, while providing communications ability and hearing protection. The NGFWH system serves as a platform for Helmet Mounted Devices (HMDs) and maintains stability to ensure HMD performance is not degraded.

This test plan documents the scope, content, methodology, sequence, management of, and responsibilities for follow-on Windblast test activities.

1.1 Purpose

This document describes the testing for the NGFWH. The purpose of this test is to determine the performance of the test assets under windblast conditions.

Performance of interest includes structural integrity and the ability of the NGFWH, to remain in position and intact during the windblast exposure.

Testing will be performed at Dayton T. Brown, Inc. (DTB), Bohemia, New York. The purpose of the test plan is to describe the methods that will be used to test and evaluate the NGFWH.

1.2 Scope

This test plan covers the follow-on windblast testing for NGFWH to be performed by Dayton T. Brown, Inc. This follow-on windblast testing will be conducted in multiple orientations on the configuration of the NGFWH system.

1.6 Test Strategy and Method

The purpose of this test is to assure engineering changes to the helmet's visor assembly, are adequate to withstand 600 KEAS windblast, to ensure the NGFWH remains intact, while providing protection to aircrew during windblast exposure to satisfy safety ejection hazards, foreign objects, eye protection, and visor requirements for the program. The successful completion of this test will demonstrate the ability of the NGFWH to satisfy performance requirements as risk reduction and to close a Category (CAT) II Deficiency Report (DR) currently on the NGFWH.

1.7 System Testing

The NGFWH, will be subjected to 2 windblast incidents in the baseline slick configuration at 600 +/- 25 KEAS, with the following parameters:

• 2 Second Minimum Duration

• ACES II (DTB Provided)

• LARD Manikin o Manikin is not required to be instrumented o Preferred Neck Type: Flexible; Acceptable Neck Type: Rigid

• Still Photographs, One Standard Speed & Two High Speed Video Cameras.

Test Number Helmet Speed Duration Manikin Pitch Yaw

1 600 KEAS 2 sec LARD 34 0

2 600 KEAS 2 sec LARD 34 0

1.8 Configuration and Procedural Details

Dayton T. Brown will set-up the test facility and test configuration to include an ACES II secured to the windblast test platform with a custom aerodynamic mounting fixture.

Normal modes of attachment will be used to restrain the test subject. Additional roles and responsibilities of Dayton T. Brown personnel include:

- Pressurize windblast system according to test requirements

- Secure the ejection seat to windblast test platform and appropriately configure according to test requirements

- Assist in hoisting manikin for dressing

- Capture pre-test photo documentation

- Assist with positioning and fixing manikin in the ejection seat

- Capture additional pre-test photo documentation with manikin fixed in the ejection seat after all test equipment has been secured, and final touches have been made

- Ensure test readiness, including test set-up complete, system pressure achieved, instrumentation/video readiness, and test area clear

- Capture post-test photo documentation

- Inspect collected data and video post-test

- Photo and video distribution

- Compose and distribute final report

Test subject for this test event is being shipped and loaned from the 711th Human Performance Wing at Wright-Patterson AFB, OH. Test subject for this test is the 95th Percentile Male Manikin (LARD) with LM-110 Head form and Neck Assembly. Manikin instrumentation for this test is not required.

LARD will be fit with MEDIUM/WIDE MBU-20/P oxygen mask and approved combination of Flight Gear provided and fit by on-site AFE manager. NGFWH will be donned by on-site contractor representatives or AFE manager. Per standard test procedure, AFE personnel will apply lipstick to the outer edges of the helmet visor to track any/all potential contacts and marks.

1.9 Equipment List

Dayton T. Brown will set-up the test facility and test configuration to include the following equipment:

• LARD Manikin (LM-110 Head form, Flexible Neck, Rigid as back-up)

• MED/WIDE MBU-20/P Oxygen Mask

• NGFWH – size Large

• ACES II

• CWU-27/P (Aircrew Flight Suit) - size 48L

• LPU-38/P (Life Preserver)

• PCU-15/P (Torso Harness)

• CRU-60P (Oxygen Connector)

Optional equipment:

• Survival Vest

• GS/FRP-2 (Aircrew Flight Gloves) - size 11

• Bellville 690 (Aircrew Flight Boots) - size 12.5

2. EVALUATION CRITERIA

The approach that will be used in establishing successful passing criteria is the NGFWH system’s ability to withstand the defined windblast conditions. The purpose of the test is to ensure the NGFWH remains intact, while providing protection to aircrew during windblast exposure to satisfy ejection hazards, foreign objects, eye protection, and visor requirements below. If a successful test is completed, it demonstrates the ability of the NGFWH to satisfy performance requirements as risk reduction for continuing ejection sled testing.

3.6.3 Ejection Hazards - The hazards attributable to the NGFWH system during the ejection acceleration events, canopy penetration phase of the ejection sequence, parachute opening shock, windblast effects, and water entry shall be minimized. HMD and Night Vision Goggles (NVGs) display functions shall not be required to operate after exposure to ejection loads. If any parts of the NGFWH system are lost during the windblast event (by chance or by design) and all the below requirements are still met, those lost parts shall not interfere with the proper operation of the ejection seat or parachute.

3.6.3.6 Foreign objects - The NGFWH system visor shall provide facial protection, prevent foreign objects from entering between the face and visor, and provide protection to the eyes; the system shall not loosen, break, or show any evidence of material failure when exposed to windblast.

3.6.6 Eye Protection - The NGFWH (in all configurations) shall shield the eyes during all flight and ground operations, from adverse effects of solar radiation, windblast, airborne debris, bailout, ditching, and 600 KEAS ejection. (T = O)

3.6.6.2 Visor - The NGFWH and visor shall be safely retained and remain in its worn position when exposed to a 600 KEAS ejection. Retention of the NGFWH during ejection is required to provide protection to the aircrew’s head and face. The visor will remain in place on the face throughout the entire windblast event. (T = O)

3.6.3.5 Physical Damage - The NGFWH system shall not crack, split, or sustain physical damage that would cause injury to the aircrew or impair the ability of the helmet to protect the aircrew.

3. TEST SCHEDULE

Test schedule is roughly outlined below, with a planned back-up day in case it is required:

• 0800 Arrive at DTB

• 0815 Dress manikin

• 0900 Pre-test photos

• 0915 Manikin secured in the ejection seat

• 0945 Test assets secured

• 1015 Final pre-test photos

• 1030 1st shot 600 KEAS

• 1045 Post-test photos

• 1100 Post-test inspection, video inspection

• 1200 Lunch provided

• 1315 Check test set-up (resecure manikin if required, etc.)

• 1345 Test assets secured

• 1415 Final pre-test photos

• 1430 2nd shot 600 KEAS

• 1445 Post-test photos

• 1500 Post-test inspection, video inspection

• 1630 Target wrap-up

This schedule will be repeated until the entire test matrix is successfully completed.

4. TEST SUMMARY REPORT

A Test Summary Report of the windblast testing will be created by DTB to document and summarize the windblast testing within approximately three (3) weeks after completion of the tests.