Training the next generation of naval aviators has always required a careful balance between realism, cost, and equipment availability – but when critical components are limited, that balance becomes harder to maintain.
For systems like the Joint Helmet Mounted Cueing System (JHMCS) visors, legacy procurement timelines could take years and cost roughly $870 per unit. According to reporting from Portfolio Acquisition Executive-Aviation, which is also known as PAE(A), this long delivery timeline and high cost created bottlenecks in training pipelines and limited access to equipment needed for hands-on training.
As the Navy continues to explore more efficient and scalable approaches to training and sustainment, additive manufacturing is emerging as a promising solution. Recent efforts around JHMCS visors reflect a broader shift toward finding new ways to support readiness, expand access to critical equipment, and better prepare aircrew for the demands of modern operations.
From improving how training equipment is produced to enabling more consistent, repeatable instruction, this approach signals a meaningful evolution in how the Navy is thinking about sustainment and readiness at scale.
To better understand how these efforts are taking shape, we recently sat down with Capt. Jonathan Schiffelbein, Naval Aviation Training Systems and Ranges Program Office (PMA-205) Program Manager, to discuss the role of JHMCS visors in aircrew training, the exploration of additive manufacturing as a solution, and what this approach could mean for future Navy and DoW sustainment strategies.
GovDesignHub (GDH): For readers who may not be familiar with naval aviation training systems, what is the JHMCS, and how does the visor component specifically factor into the JHMCS system? Why is it a critical part of aircrew training equipment?
Capt. Jonathan Schiffelbein: The JHMCS is a state-of-the-art helmet-mounted display system designed to enhance aircrew capabilities across fighter pilot operating platforms.
The JHMCS visor serves as the display medium, projecting critical flight, navigation, and targeting information directly into the pilot’s field of view. These visors also allow operators to practice shaping techniques in a controlled environment, reducing risk to fleet equipment while ensuring standardized training.
This innovative approach not only enhances readiness but also significantly improves situational awareness and mission effectiveness. By integrating visual data directly into the pilot’s line of sight, JHMCS enables rapid decision-making, faster target engagement, and more reliable identification of friendly forces – all of which are essential for operational success and survivability in high-stakes environments.
GDH: Before this initiative, how were legacy JHMCS visors sourced, and what limitations did that procurement model introduce for training pipelines and fleet readiness?
Capt. Jonathan Schiffelbein: Prior to this initiative, JHMCS visors were not specifically sourced for training purposes. Recognizing the importance of sustaining this critical equipment, 3D-printed visors were introduced into the Aircrew Survival Equipmentman—also known as Parachute Riggers (PRs)—training pipeline.
The introduction of 3D-printed visors for training has transformed how the PRs develop their skills. These visors create a controlled environment for standardized, hands-on training, eliminating reliance on operational equipment and reducing the risk of damage to critical fleet assets.
“Recognizing the limitations of sourcing high-cost consumables for the schoolhouse, the team proposed additive manufacturing as an alternative” –Capt. Jonathan Schiffelbein
This approach not only safeguards mission-critical components but also expands the pool of trained personnel, ensuring aircrew have the equipment they need to perform their missions effectively.
GDH: At what point did the idea of using additive manufacturing move from a possibility to a viable solution worth pursuing? Were there early concerns or misconceptions about using 3D-printed components in aircrew training equipment, and how did the team address those internally?
Capt. Jonathan Schiffelbein: Recognizing the limitations of sourcing high-cost consumables for the schoolhouse, the team proposed additive manufacturing as an alternative and collaborated with PAE(A) to assess its feasibility.
This partnership confirmed that 3D-printed visors could be produced specifically for training purposes, enabling PRs to practice shaping techniques without relying on operational fleet equipment.
GDH: What success criteria did the team establish at the beginning—both technically and operationally—to ensure that these 3D-printed JHMCS visors would truly support the fleet?
Capt. Jonathan Schiffelbein: To ensure the 3D-printed JHMCS visors would effectively support the fleet, the team established clear technical and operational success criteria. Technically, the visors needed to replicate the feel and behavior of genuine visors during shaping, providing PRs with a realistic training experience that would prepare them to handle operational equipment with confidence.
“The additive manufacturing process for the JHMCS visor was a collaborative effort, progressing from design and prototyping to final production to ensure the visors met technical specifications, provided a realistic shaping experience, and supported fleet readiness.” –Capt. Jonathan Schiffelbein
Operationally, the visors were designed to integrate seamlessly with the JHMCS Helmet Display Unit and helmet, enabling operators to conduct fit checks and verify proper shaping techniques in a controlled training environment.
These criteria were critical for ensuring that users could develop proficiency in shaping and fitting techniques before entering fleet operations. By meeting these standards, the visors reduce risks to operational equipment, safeguard mission-critical components, and ensure aircrew have properly prepared visors to perform their missions effectively.
GDH: Can you walk through the additive manufacturing process used for the JHMCS visor – from design and prototyping through final production?
Capt. Jonathan Schiffelbein: The additive manufacturing process for the JHMCS visor was a collaborative effort, progressing from design and prototyping to final production to ensure the visors met technical specifications, provided a realistic shaping experience, and supported fleet readiness.
The process began with the team providing a visor, Helmet Display Unit, and relevant specifications. Using these inputs, 3D scans of the visor were created, and a model was developed, optimized for additive manufacturing.
“The use of additive manufacturing for JHMCS visors has delivered significant benefits, including a 65 percent cost savings and reduced delivery timelines.” –Capt. Jonathan Schiffelbein
Several prototypes were produced using different materials and were rigorously tested to determine which best replicated the shaping experience of a genuine JHMCS visor. Acrylonitrile Butadiene Styrene (ABS) was ultimately selected as the most representative material due to its ability to mimic the behavior of operational visors during shaping exercises.
Once the material was finalized, the visor underwent additional testing to ensure it met fleet training requirements.
GDH: The team selected ABS as the material for the prototype visor. What performance, durability, or manufacturability factors drove that choice?
Capt. Jonathan Schiffelbein: The selection of ABS was driven primarily by its performance – specifically, its superior ability to replicate the feel and material properties of a genuine JHMCS visor during the shaping process.
“This initiative demonstrates the transformative potential of additive manufacturing to meet critical training requirements.” –Capt. Jonathan Schiffelbein
In addition, ABS provides a reliable, cost-effective, and scalable solution for producing these training aids. Its durability is well-suited for the rigors of a schoolhouse environment, and its manufacturability ensures the visors can be produced efficiently.
GDH: The Navy reported a 65 percent cost savings and a delivery timeline reduced from years to weeks with this 3D printing approach. How do those improvements translate into real-world benefits for instructors, students, and the fleet? Do you envision additive manufacturing being applied more broadly across Navy and DoD training and sustainment programs?
Capt. Jonathan Schiffelbein: The use of additive manufacturing for JHMCS visors has delivered significant benefits, including a 65 percent cost savings and reduced delivery timelines. It has also ensured that every trainee has access to an individual visor for shaping practice, allowing instructors to assess each student’s proficiency without needing to reuse previously shaped visors.
This initiative demonstrates the transformative potential of additive manufacturing to meet critical training requirements. The Navy will remain laser-focused on delivering the training Sailors need to meet the demands of the Fleet.
Featured image courtesy of U.S. Navy, depicting a sailor getting fitted with a new cutting-edge 3D-printed JHMCS visor.
