3_160711_-_ECH_FAT_Event_Design_Plan_DRAFT.pdf

First Article Test (FAT) Event Design Plan for the

Enhanced Combat Helmet

Submitted By

ECH Engineer

Program Manager Infantry Combat

Equipment

Date

ECH Team Lead

Approval

First Article Test (FAT) Event Design Plan

For Enhanced Combat Helmet

Coordination with

U.S. Marine Corps Operational Test and

Evaluation Activity

Deputy Under Secretary of the Army

Test and Evaluation

Staff Specialist

Director, Live Fire Test and Evaluation

Record of Change

Version Date Paragraph Comment Approval

- TBD N/A Initial Release See signature page

DRAFT as of 08 Jul 16

ECH FAT Event Design Plan

1. Part I -- System Introduction

a. Mission Description. The Enhanced Combat Helmet (ECH) will assist Marines, soldiers and sailors by providing head protection as they close with and destroy the enemy through fire and maneuver. Missions include the entire range of military operations.

b. Measures of Effectiveness and Suitability. TABLE 1 lists the operational effectiveness and suitability capabilities required by the U.S. Marine Corps Urgent Statement of Need

(USON), dated 02 March 2009, Change 1 dated 29 June 2010, Change

2 dated 11 August 2010, Change 3 dated June 2012, and Change 4 dated 24 March 2014.

TABLE 1. ECH Operational Capabilities

Operational Effectiveness

Weight

The overall weight of each ECH

(including the shell, suspension, and retention systems, and necessary attachment hardware) shall not exceed 5% of the weight of the current Lightweight Helmet

(LWH) in the same configuration

(T); less than the LWH (O).

USON

Attribute 1

Small Arms

Protection

The ECH shall provide greater protection against small arms than the current LWH (T), using V50 as the metric.

USON

Attribute 2

Fragmentation

Protection

The ECH shall provide at least 35% better fragmentation protection when compared to the LWH (T) and

100% better fragmentation protection (O).

Attribute 3

Flammability

The ECH shall be noncombustible and flame resistant to flash fire situation and not drip.

Attribute 6

Operational Suitability

Ergonomics

The ECH shall ergonomically accommodate the 2nd percentile female through the 98th percentile male of Marines (T=O)

USON

Attribute 4

MC Fit

Policy

Operational

Conditions

The ECH shall be as durable as the

LWH (T) and will operate in all weather and environment conditions

(T=O).

Attribute 7

Integration

The ECH shall not degrade or interfere with current equipment employed by the Marine on the battlefield.

Attribute 5

Note: T - Threshold and O - Objective

d. System Description. The ECH will provide Marines, soldiers and sailors improved ballistic protection over the current LWH and ACH. The ECH is intended to have the same size, shape and weight as the ACH. As a helmet, the ECH will provide an increased level of fragmentation protection as well as increased small arms protection (the 9 mm protection requirement remains the same). Each helmet consists of a finished shell, suspension system, retention system, and necessary attachment hardware.

FIGURE 1. ECH with IRS Retention System

e. Enhanced Combat Helmet Components. The helmet assembly shall meet the design requirements of the ECH Purchase

Description (PD) Version L, referenced drawings, and parts lists. The ECH assembly shall be in four sizes: Small (S), Medium (M), Large (L), Extra-Large (XL). A complete helmet assembly typically consists of the following components:

- Helmet Shell

- Suspension Hook Disks

- Suspension Pads (3/4 - inch thick) (mandatory source)

- Improved Retention Assembly (IRS) (mandatory source)

- Attaching Hardware

- Edging, Finish, and Labels

f. Critical Technical Parameters. The ECH PD (Reference 1) specifies the technical requirements and associated evaluation criteria. A spreadsheet that summarizes the ECH PD requirements for FAT and includes the associated evaluation criteria and FAT test article quantities is provided in Appendix A.

2. Part II -- Integrated FAT Program Summary

a. Integrated Test Program Schedule for FAT

FIGURE 2. ECH Integrated Program Schedule

(FRP = Full Rate Production; IOC = Initial Operational Capability)

b. Management. The Program Manager, Infantry Combat

Equipment (PM ICE), Body Armor and Load Bearing Equipment (BALB)

Team is responsible for providing oversight for all ECH Test and

Evaluation (T&E) events including FAT. The Team is responsible for establishing this FAT Event Design Plan (EDP) to outline required ballistic and non-ballistic tests and associated sampling (or test article) criteria. This FAT Event Design Plan has been reviewed and approved by the T&E Integrated Product

Team.

For FAT, responsibilities of the T&E WIPT include review of final detailed test plans and procedures, test protocols, test results and test reports. The ECH Team and T&E WIPT will be responsible for reviewing and adjudicating test issues and test results against the approved detailed FAT plans and test procedures approved by Director of Live Fire Test and Evaluation

(LFT&E) at the Office of the Secretary of Defense, Director of

Operational Test and Evaluation (DOT&E). A listing of the organizational membership to the T&E WIPT and the T&E FAT sub-

WIPT including the associated responsibilities for each organization are further defined in the Test and Evaluation

Strategy for Enhanced Combat Helmet (Reference 3) and the

Charter for the Enhanced Combat Helmet (ECH) Test and Evaluation

Working-level Integrated Product Team (T&E WIPT).

3. Part III – First Article Test and Evaluation Outline

a. Objectives

(1) To verify production helmets against the ECH PD

(Reference 1).

b. FAT and Evaluation. FAT will be conducted on helmet designs that are submitted by the contractor for production evaluation. To ensure that minimum performance requirements are met, testing and verification will be in accordance with the approved ECH PD for FAT (Reference 1). A spreadsheet that summarizes the ECH PD requirements for FAT and includes the associated evaluation criteria and FAT test article quantities is provided in Appendix A. All contractor-submitted FAT test articles, including spares, will be shipped to Aberdeen Test

Center (ATC) located in Aberdeen, MD for storage until FAT is completed and the final FAT report is issued. All testing will be conducted by ATC but may include other Government laboratories. All ballistic testing will be at ATC. Once testing begins, FAT is planned to be completed within 60 days thereafter. FAT will consist of two distinct test events: 1) ballistic testing and 2) non-ballistic testing. While testing is underway, ATC will make accommodations for Team witnesses.

There will be no Government Reference Testing during FAT with the exception of thickness measurements during environmental conditioning. This may include no Small Arms Backface Transient

Deformation (BTD) measurements or 45 degree V50 testing.

At the conclusion of FAT, ATC will provide FAT status of testing and preliminary FAT results for review to the BALB Team and T&E

WIPT members in preparation for a Data Assessment Conference

(DAC). Actions, findings and scoring decisions will be documented in the T&E WIPT DAC meeting minutes. The meeting minutes will then be forwarded to the ECH Team and T&E WIPT for review. After FAT is completed and the final ATC FAT report has been issued, at ECH Team direction, ATC will ship all test articles back to the appropriate submitting contractor.

(1) Ballistic Testing – FAT

(a) Test Planning. Under an established Statement of Work (SOW) and based on this approved FAT Event Design Plan, ATC will develop a FAT ballistic detailed test plan with a classified annex (if required) that the BALB Team and T&E WIPT, Program Manager, and DOT&E will review and approve. The detailed ballistic test plan will be in accordance with the ECH

PD (Reference 1), the DOT&E Military Combat Helmet Standard for

Ballistic testing, and the Test Operating Procedures (TOP 10-2-

217 Ballistic Testing of Helmets) (Reference 2) as approved for

FAT. A joint Test Readiness Review (TRR) will be conducted with

PM ICE, ATC, and DOT&E. The objective of the TRR will ensure all testing assets and resources are available for FAT.

(b) Objectives. To verify that the test articles submitted for the ECH program meet the ballistic contractual specifications outlined in the ECH PD. Subset objectives to the overall ballistic objective are as follows:

1. To verify that the ballistic performance of the submitted ECH system meets the fragmentation protection measured by V50 BL(P) requirements set forth in the ECH PD.

2. To verify that the submitted ECH (shell and hardware) meets the Resistance to Penetration (RTP) ballistic performance requirement against 9 mm bullets in the ECH PD as measured by RTP testing.

3. To verify that the submitted ECH meets the

BTD performance requirement against 9 mm bullets set forth in the ECH PD, as determined by back face deformation measurements.

4. To verify that the submitted ECH meets RTP ballistic performance requirement against small arms projectiles

(Threat M) in the ECH PD Classified Annex A.

5. To verify that the ballistic performance of the submitted ECH system meets the small arms protection (Threat

M) as measured by V50 BL(P) requirements set forth in the ECH PD

Classified Annex A.

(c) Execution. Testing will be in accordance with the ECH PD (Reference 1) and the TOP 10-2-217 Ballistic Testing of Helmets (Reference 2) as approved for FAT. All ballistic testing will be under the supervision of Government personnel and the ECH Team. ECH Team representative(s) will be present at the ballistic test events, as necessary.

(d) Reporting. Under an established SOW, ATC will execute the approved FAT ballistic detailed test plan and submit preliminary data, draft and final reports to the ECH Team on the results of the testing. Three calendar work days after testing is completed for any specific ballistic PD requirement has been completed, preliminary data from that testing will be submitted by ATC to the BALB Team for review. A follow-on draft report will be submitted by ATC to the BALB Team for review and comment within 14 calendar days after completion of all ballistic testing and will be used to adjudicate any test result discrepancies. An overall final ballistic test report will be submitted by ATC to the BALB Team within 45 days after overall ballistic test completion. ATC is responsible for assessing the test data in accordance with the criteria of the approved ECH PD

(Reference 1) and associated spreadsheet found in Appendix A.

If there are noted discrepancies between the DAC and the ATC report, the DAC will prepare a Memorandum for Record to address the discrepancies. [Note: Non-ballistic testing will be conducted concurrently with ballistic testing.]

(2) Non-Ballistic Testing – FAT

(a) Test Planning. Under an established SOW and based on this approved FAT EDP, ATC will develop a FAT non-ballistic detailed test plan that the T&E WIPT will review and approve. Testing will be in accordance with the ECH PD as approved for FAT and in accordance with applicable standards.

(b) Objectives. To verify that the test articles submitted for the ECH program meet the non-ballistic contractual specifications outlined in the ECH PD. Subset objectives to the overall non-ballistic objective are as follows.

1. To verify the test articles, upon delivery and prior to testing, are complete, undamaged, and ready for testing.

2. To verify overall system weight does not exceed performance requirements.

3. To verify the bump or blunt impact protection does not exceed performance requirements.

4. To verify the complete helmet assembly meets the design requirements of the ECH PD (i.e., size, shape, shell construction, shell thickness, shell uniformity, benchmarks, attachment holes, edging, coating, retention system, pad suspension system, hook disks, etc.).

5. To verify that helmet components are interchangeable and modular such that replacement of any component with another like-sized unit shall have no detrimental effect on any of the ECH PD requirements.

6. To verify infrared reflectance meets ECH PD requirements.

7. To verify specular gloss meets ECH PD requirements.

8. To verify that all helmet components are constructed in such that they can withstand various environmental extremes without degradation and meet operating environment requirements as specified in the ECH PD (i.e., seawater resistance, weatherometer resistance, field agent resistance, flame resistance, high temperature storage and use, cold temperature storage and use, temperature shock, altitude, vibration, impact resistance, compression resistance, salt fog, etc.).

9. To verify that the ECH is compatible with the NVG Bracket and that the contractor-supplied bolt meets requirements.

10. To verify ownership and support requirements as specified in the ECH PD (i.e., marking, barcode label, washability/colorfastness, accelerated aging/shelf life, health/safety, workmanship, etc.).

(c) Execution. All non-ballistic testing will be conducted by ATC in accordance with the ECH PD as approved for

FAT. All non-ballistic testing will be under the supervision of

Government personnel and the ECH Team. ECH Team representative(s) will be present at the non-ballistic test events, as necessary.

(d) Reporting. Under an established SOW, ATC will execute the approved FAT non-ballistic detailed test plan and submit preliminary data, draft and final reports to the ECH Team on the results of the testing. Three calendar work days after testing is completed for any specific non-ballistic PD requirement has been completed, preliminary data from that testing will be submitted by ATC to the ECH Team for review.

ATC will submit a follow-on draft report to the ECH Team for review and comment within 14 calendar days, and those comments will be used to adjudicate any test result discrepancies. ATC will submit an overall final non-ballistic test report to the

ECH Team within 45 days after overall non-ballistic test completion. ATC is responsible for assessing the test data in accordance with the criteria of the approved ECH PD (Reference

1) and associated spreadsheet found in Appendix A. If there are noted discrepancies between the DAC and the ATC report, the DAC will prepare a Memorandum for Record to address the discrepancies. [Note: Ballistic testing will be conducted concurrently with non-ballistic testing.]

4. Part IV -- FAT and Evaluation Resource Summary

a. Summary

TABLE 3. Quantity of FAT Test Articles

Test Event Unfinished

Shells

Finished

Shells

Finished

Helmets

FAT 24 171 273

(1) Test Articles. Test articles will be considered production-representative models and/or production-representative components. Test articles that are considered production-representative models will be configured as an unfinished shell, finished shell, or finished helmet according to the detailed FAT plans. Per the ECH PD, the test articles considered as production-representative models are defined as:

(a) Unfinished shell – a helmet shell that shall include the raw shell only, drilled with attachment holes (no primer, paint (coating), texturing aggregate, edging, edging adhesive, or hook disks).

(b) Finished shell - a helmet shell that shall include the unfinished shell, any primer, paint (coating) and texturing aggregate, all necessary attachment holes, any edging and adhesive to hold the edging, and labels.

(c) Finished helmet – a helmet that includes the finished shell, hook disks, a complete pad set (mandatory source), a complete retention system (mandatory source), and attaching hardware.

(2) Test Sites and Instrumentation. Test ranges/facilities to be used for each type of testing will be in accordance with the approved detailed FAT plans and the ATC IOP

PED-003 (Reference 2), other ATC Test Operating Procedures, and/or commercial standards. The PM ICE has a current SOW with

ATC.

(3) FAT Funding Requirements. Table 4 identifies the estimated funding required for the planned FAT. Totals assume four contractor designs submitted for FAT.

TABLE 4. FAT Funding Required

Event FY17($K)

FAT 375

A-1

Appendix A: FAT Helmet Quantities and Allocation

T es t N u m b er

E C

H R eq m n t

P a ss

/F a il ri te

V if ic a ti o n

M et h d

S m p li g n d it io

B ll is ti c

P ro je ct il e

Unfinished

Shell Finished Shell

Finished Helmet w/ IRS

S M L XL S M L

X

L S M L XL

Interchangeabilit y

Any nonconformance to requirement constitutes test failure.

CoC NA NA NA

Shell

Design/Shape

Any nonconformance to measurement requirement constitutes test failure.

Test

(2 samples per each size)

Ambient NA 2 2 2 2

Shell

Construction

No critical defects. No more than 4% major and 12% minor defects.

Visual Exam

(5 samples per each size)

Ambient NA 5 5 5 5

Shell Thickness and Uniformity

No critical defects. No more than 4% major defects

Test / Visual

Exam

(3 samples per each size)

Ambient NA 3 3 3 3

5 Benchmarks No more than 12% minor defects

Test / Visual

Exam

(5 samples per each size)

Ambient NA 5 5 5 5

Attachment

Holes

No critical defects. No more than 4% major and 12% minor defects.

Test / Demo

(5 samples per each size)

Ambient NA 5 5 5 5

Retention System

Holes

Any nonconformance to requirement constitutes test failure.

Test

(5 samples per each size)

Ambient NA 5 5 5 5

Night Vision

Device Hole(s)

Any nonconformance to requirement constitutes test failure.

Test

(5 samples per each size)

Ambient NA 5 5 5 5

A-2

T es t N u m

H R eq m n t

P a ss

/F te if ic a ti h m p li n d it ll is ti c

P ro je ct il e

Unfinished

Shell Finished Shell

Finished Helmet w/ IRS

S M L XL S M L

X

L S M L XL

9 Edging No more than 4% major and

12% minor defects.

Visual Exam

/ Test

(5 samples per each size)

Ambient NA 5 5 5 5

10 Edging Adhesion

Any nonconformance to requirement constitutes test failure.

Test

(5 samples per each size)

Ambient NA 5 5 5 5

Edging Adhesion

After Heat Aging

Any nonconformance to requirement constitutes test failure.

Test

(1 sample per each size)

Ambient NA 1 1 1 1

12 Coating No more than 4% major and

12% minor defects.

Visual Exam

(5 samples per each size)

Ambient NA 5 5 5 5

Surface

Preparation Certificate of Compliance CoC NA Ambient NA

Texturing of

Coating Certificate of Compliance CoC NA Ambient NA

15 Sand Texturing Certificate of Compliance CoC NA Ambient NA

Walnut Shell

Flour Texturing Certificate of Compliance CoC NA Ambient NA

17 Color

Any nonconformance to requirement constitutes test failure.

Visual Exam

(5 samples per each size)

Ambient NA 5 5 5 5

Infrared

Reflectance See Below Test See Below Ambient NA

Infrared

Reflectance -

Texturing and

Any nonconformance to requirement constitutes test failure.

Test

(1 sample per each size)

Ambient NA 1 1 1 1

A-3

T es t N u m

H R eq m n t

P a ss

/F te if ic a ti h m p li n d it ll is ti c

P ro je ct il e

Unfinished

Shell Finished Shell

Finished Helmet w/ IRS

S M L XL S M L

X

L S M L XL

Coating of

Finished Shell

19 Specular Gloss

Any nonconformance to requirement constitutes test failure.

Test

(1 sample per each size)

Ambient NA 1 1 1 1

Adhesion of

Coating

Any nonconformance to requirement constitutes test failure.

Test

(3 random locations per sample)

Ambient NA 1

21 Retention System See AR-PD 12-01 Visual Exam

20 X-back, 20

IRS

(5 samples per each size)

Ambient NA

Retention System

Attachment

Points

Any nonconformance to requirement constitutes test failure.

Visual Exam

/ Test

20 X-back, 20

IRS

(5 samples per each size)

Ambient NA 5 5 5 5

Retention System

Attachment

Hardware*

No more than 4% major and

12% minor defects. See also

AR-PD 12-01

Visual Exam, Test

20 X-back, 20

IRS

(5 samples per each size)

Ambient NA 5 5 5 5

NVD Bracket and Attaching

Hardware

No more than 4% major and

12% minor defects.

Visual Exam, Test

(5 samples per each size)

Ambient NA 5 5 5 5

Pad Suspension

System

No more than 4% major and

12% minor defects.

Test

18 (6 samples per each pad type)

Ambient NA

A-4

T es t N u m

H R eq m n t

P a ss

/F te if ic a ti h m p li n d it ll is ti c

P ro je ct il e

Unfinished

Shell Finished Shell

Finished Helmet w/ IRS

S M L XL S M L

X

L S M L XL

26 Pad Construction No more than 4% major and

12% minor defects.

Test

18 (6 samples per each pad type)

Ambient NA

Inner Layer

Material

Any nonconformance to requirement constitutes test failure.

Test

5 specimens (1 in x 5 in size of each specimen)

Ambient NA

Padding Layer

Material

Any nonconformance to requirement constitutes test failure.

Test

6 (2 samples per each pad type)

Ambient NA

Outer Layer

Material

Any nonconformance to requirement constitutes test failure.

Test

6 (2 samples per each pad type)

Ambient NA

Pad Compression

Durability

Any nonconformance to requirement constitutes test failure.

Test

9 (3 samples per each pad type)

Ambient NA

31 Hook Disks No critical defects. No more than 12% minor defects.

Test

(1 sample per each size)

Ambient NA 1 1 1 1

Hook Disk Shape and Coverage

Any nonconformance to requirement constitutes test failure.

Test

(1 sample per each size)

Ambient NA 1 1 1 1

Hook Disk

Durability

Any nonconformance to requirement constitutes test failure.

Test

(1 sample per each size)

Ambient NA 1 1 1 1

Hook/Loop

Adhesion

Any nonconformance to requirement constitutes test failure.

Test 5 specimens tested

A-5

T es t N u m

H R eq m n t

P a ss

/F te if ic a ti h m p li n d it ll is ti c

P ro je ct il e

Unfinished

Shell Finished Shell

Finished Helmet w/ IRS

S M L XL S M L

X

L S M L XL

V50 Ballistic

Protection Limits

Failure to meet the minimum

V50 requirements in paragraph 3.10.1 shall constitute a test failure.

Test See DOTE

Protocol

Ambient, Hot, Cold, Seawater

Various

RCC

FSP

18 26 20 18

RTP - 9mm

(Shell) See DOTE Protocol Test

See DOTE

Protocol

Ambient, Hot, Cold, Seawater 9mm 12 12 12 12

BTD (9mm

Shell)*

See DOTE Protocol Quantity listed assumes no size or environment is a significant factor. If size and/or environment are significant, additional helmet samples will be required.

Test See DOTE

Protocol

Ambient, Hot, Cold, Seawater 9mm

In cl ab v e

In cl ab v e

RTP - 9mm

(Retention

System

Hardware)

See DOTE Protocol Test See DOTE

Protocol

Ambient, Hot, Cold, Seawater 9mm 8 9 8 8

RTP - 9mm

(NVD Hardware)

90% CL that 90% no penetration. Aggregated across all environmental conditions and sizes

Test

22 shots distributed among sizes and environments

Ambient, Hot, Cold, Seawater 9mm 5 6 6 5

RTP - Small

Arms (Threat M) See DOTE Protocol Test

See DOTE

Protocol

Ambient, Hot, Cold, Seawater

Small

Arms

(Threat

M)

16 17 16 16

A-6

T es t N u m

H R eq m n t

P a ss

/F te if ic a ti h m p li n d it ll is ti c

P ro je ct il e

Unfinished

Shell Finished Shell

Finished Helmet w/ IRS

S M L XL S M L

X

L S M L XL

41 Weight*

Any nonconformance to requirement constitutes test failure.

Test All finished helmet samples Ambient NA

Blunt Impact

Protection

90% of indentation measurements and accelerations are less than indentation, or fracture, or acceleration requirements at

90% CL. Indentation and acceleration CLs will be calculated separately.

Aggregated across all environmental conditions.

Test

(7 locations per finished helmet)

Ambient NA 1 1 1 1

Blunt Impact

Protection

90% of indentation measurements and accelerations are less than indentation, or fracture, or acceleration requirements at

90% CL. Indentation and acceleration CLs will be calculated separately.

Aggregated across all environmental conditions.

Test

(7 locations per finished helmet)

Extreme Hot

(130 deg F)

NA 1 1 1 1

A-7

T es t N u m

H R eq m n t

P a ss

/F te if ic a ti h m p li n d it ll is ti c

P ro je ct il e

Unfinished

Shell Finished Shell

Finished Helmet w/ IRS

S M L XL S M L

X

L S M L XL

Blunt Impact

Protection

90% of indentation measurements and accelerations are less than indentation, or fracture, or acceleration requirements at

90% CL. Indentation and acceleration CLs will be calculated separately.

Aggregated across all environmental conditions.

Test

(7 locations per finished helmet)

Extreme Cold

(14 deg F)

NA 1 1 1 1

Seawater

Resistance

Any nonconformance to requirement constitutes test failure.

Test

(random sizes) Ambient NA 1 1

Weatherometer

Resistance

Any nonconformance to requirement constitutes test failure.

Test

(random sizes) Ambient NA 1 1

Field Agent

Resistance

Any nonconformance to requirement constitutes test failure.

Test 1 test per agent Ambient NA 2 2 3 2

48 Flame Resistance

Any nonconformance to requirement constitutes test failure.

Test 6 crown, 6 edge Ambient NA 1 1 1

High

Temperature

Storage and Use

Any nonconformance to requirement constitutes test failure.

Test

(random sizes)

Extreme Hot

(160 deg F)

NA 1

Cold

Temperature

Storage and Use

Any nonconformance to requirement constitutes test failure.

Test

(random sizes)

Extreme Cold (-

60 deg F)

NA 1

A-8

T es t N u m

H R eq m n t

P a ss

/F te if ic a ti h m p li n d it ll is ti c

P ro je ct il e

Unfinished

Shell Finished Shell

Finished Helmet w/ IRS

S M L XL S M L

X

L S M L XL

Temperature

Shock

Any nonconformance to requirement constitutes test failure.

Test

( random sizes)

Extreme Hot

(160 deg F) to

Extreme Cold (-

60 deg F)

NA 1

Temperature

Shock

Any nonconformance to requirement constitutes test failure.

Test

(random sizes)

Extreme Cold (-

60 deg F) to

Extreme Hot

(160 deg F)

NA 1

53 Altitude

Any nonconformance to requirement constitutes test failure.

Test

(random sizes)

Altitude - Temp

& Pressure

NA 1 1

54 Vibration

Any nonconformance to requirement constitutes test failure.

Test

1 sample randomly selected

Ambient NA 1

Impact

Resistance

50% CL / 90% no deformation is less than requirement.

Test

(2 samples of each of four finished helmet sizes)

Ambient NA 2 2 2 2

Compression

Resistance (Top to Bottom)

50% CL / 90% no dimensional change is greater than requirement.

Test

(2 samples of each of four finished shell sizes)

Ambient NA 2 2 2 2

A-9

T es t N u m

H R eq m n t

P a ss

/F te if ic a ti h m p li n d it ll is ti c

P ro je ct il e

Unfinished

Shell Finished Shell

Finished Helmet w/ IRS

S M L XL S M L

X

L S M L XL

Compression

Resistance (Side to Side)

50% CL / 90% no dimensional change is greater than requirement.

Test

(2 samples of each of four finished shell sizes)

Ambient NA 2 2 2 2

58 Salt Fog

Any nonconformance to requirement constitutes test failure.

Test

1 randomly selected from range of four finished helmet sizes

Ambient NA 1

Marking of

Helmet Shell

Any nonconformance to requirement constitutes test failure.

Test

(1 sample from each of four finished helmet sizes)

Ambient NA 1 1 1 1

Marking of Pad

Suspension*

Any nonconformance to requirement constitutes test failure.

Visual Exam

(1 sample from each of four finished helmet sizes)

Ambient NA 1 1 1 1

61 Barcode Label*

Any nonconformance to requirement constitutes test failure.

Visual Exam

30 randomly selected

Packages of all arriving at test site

A-10

T es t N u m

H R eq m n t

P a ss

/F te if ic a ti h m p li n d it ll is ti c

P ro je ct il e

Unfinished

Shell Finished Shell

Finished Helmet w/ IRS

S M L XL S M L

X

L S M L XL

62 Washability No more than 4% major and

12% minor defects.

Test

1 randomly selected from range of four finished helmet sizes

Ambient NA 1

102 Colorfastness

Any nonconformance to requirement constitutes test failure.

Test

Textile materials used hook disks(without pads)

Ambient NA

Accelerated

Aging/Shelf

Life*

Any nonconformance to requirement constitutes test failure.

Test

(1 sample from each of four finished helmet sizes)

Ambient NA 1 1 1 1

104 Safety Certificate of Conformance CoC NA Ambient NA

105 Toxicity Certificate of Conformance CoC NA Ambient NA

Hazardous

Materials Certificate of Conformance CoC NA Ambient NA

IRS See AR-PD 12-01 12

For the ECH PD: List of materials required: 6 samples of each shape pad, 8 specimens (2 in x 6 in size of each specimen) of the loop material (inner layer), 8 specimens (1 in x 5

in) of the hook used in the hook disks, 8 specimens (25mm x 130mm) of the Pad Inner Material in the machine direction and 8 in the cross-machine direction, 2” x 6’ piece of hook disk material

A-11

T es t N u m

H R eq m n t

P a ss

/F te if ic a ti h m p li n d it ll is ti c

P ro je ct il e

Unfinished

Shell Finished Shell

Finished Helmet w/ IRS

S M L XL S M L

X

L S M L XL

For the IRS Retention System: List of materials required: in addition to the 12 medium ECH w/ IRS installed listed above: 4 loose IRS, 1 spool of thread, 60 ft of nylon webbing, 5 samples of laminated foam, and 5 each male and female side release buckles. Note that samples for the Hardware RTP ballistic test are listed in line 38.

RTP - 9mm NVD Hardware testing (item 39) requires 22 valid shots. 25 brackets and the corresponding number of sets of hardware shall be supplied.

Note that some helmets are used for multiple tests:

- Items 1 thru 8 use the same 20 helmets (5 each size, 4 sizes)

- Items 9, 10 and 12 use the same 20 helmets (5 each size, 4 sizes)

- Items 22 thru 24 use the same 20 helmets (5 each size, 4 sizes)

- Items 31 thru 33 use the same 4 helmets (1 each size, 4 sizes)

V50 ballistic testing quantities assume 2 helmets for the 2, 4, 16, and 17 grain tests, 4 for the 64 gr, and 6 for Threat M.

Sub-Total 5 5 5 5 38 45 40 36 58 73 61 57

Spares 1 1 1 1 3 3 3 3 6 6 6 6

Total

6 6 6 6 41 48 43 39 64 79 67 63

REFERENCES

References

1) ECH PD Revision L, 07 Jul 16

2) Draft DOTE ECH Protocol, 08 Jul 16

3) Test and Evaluation Strategy for Enhanced Combat Helmet