Innovation – A View Starting From a Design Brief (new RAF virtual reality kit)

This innovation example comes from the design perspective starting with a “design brief”. A good design brief is key to understanding and then achieving what the client wants.

• The main elements of this virtual reality headset design brief were to:
• Protect the sensitive electronics in the head and handsets from handling (and dropping) while in use
• give a comfortable fit for a range of heads and hands
• create an appearance that reflects high-tech, robustness, and reliability
• Be economically manufactured in batches of 10′s

If you look closely at the images of the headset in the photo you’ll see that the headset and tracking unit are separate bought in components: By using existing technology in this way The customer was able to benefit from development of full visual and audio systems without incurring the cost. This systems approach to design is particularly suitable for large projects or small projects on a tight timescale as it reduces risk and speeds up the design process.

Previous designs for one offs used SLS (selective laser sintered) models, finished and sprayed. These allowed the designers to deliver strong working parts with no tooling cost. It must be remembered that this method is not a cost effective solution for multiple parts. For the headsets and rubber parts vacuum casting (plastic like polyurethane mouldings using soft, silicone tooling) was chosen since it gives a superb finish and a strong part that can withstand the rough handling the Royal Air Force will give it.

A comfortable fit to a range of heads was delivered by learning from Ski goggles which use a single, wide, elastic strap. They developed the form of the headset by making small modifications and building the headset in their 3D printer and re-testing, although this process uses a lot of material, it is an effective way of developing and testing parts quickly. Using the latest CAD system means making changes to existing files and re-modelling is an efficient way to work.

Important early design decisions reduced cost, eased assembly, and improved performance. They opted to make the casework as small as possible by closely skinning the internal components. They decided to remove the speakers from their supplied casework and secure them in a fixed position pointing directly at the ear (rather than sitting in the ear) – this removes two additional components and potential points of weakness.

Once Canard Design Ltd had an outline design they focussed on how the parts could be manufactured. The headset was built in 3 parts that slotted together. The sub assembly is held together with self tapping screws. They worked closely with Amtech rapid prototyping to bend the Vac-casting rules and create undercuts, and tight tolerances to retain the cables on the sides without additional components or unsightly detail.

The hand tracking units look unconventional, their purpose is to sense gripping using existing technology in an innovative way; a simple design that didn’t need adjusting and did not restrict the users movement. They worked with Maelstrom, who sourced the technology and built an initial demonstration rig to develop a working rig before working closely with Amtech to overmould and seal the electronics within the rubber casework.

Maelstrom are a VR Systems Development company that produce advanced technological simulators and entertainment systems for a host of blue chip clients across the globe. The link here shows the whole Parachute simulation they designed and developed of which the headset and handset where a small part.


Canard Design Ltd is a Materials KTN member http://www.canard-design.co.uk