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Expleo supports Thales in the customisation of helmets for helicopter pilots

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Paris, 30 June 2022 – Expleo, the global engineering, technology and consultancy service provider, is providing its engineering expertise to Thales, a major European defence manufacturer and recognised leader in head-up display helmet systems, to customise flight helmets for helicopter pilots, to reduce fatigue and improve endurance during missions.

Developed by Thales, the TopOwl Digital Display helmet is tailor-made to each pilot. The helmets implement multiple advanced functionalities developed by Thales, including fluid and simultaneous transition between day and night modes, and the head-up display of flight data, all of which rely on a precise fit.

Thales TopOwl Digital Display helmets in cockpit
Eric Raze / Copyright©Thales
Thales TopOwl Digital Display helmets
Eric Raze / Copyright©Thales

To achieve this, a cover at the bottom of the helmet is shaped to fit the wearer’s head perfectly. Expleo has developed with Thales a process to adapt helmets to each wearer. A 3D scanner accurately maps the head and face in real-time, whilst 3D manufacturing guarantees each helmet is a precise fit for the individual.

To support the needs of pilots in the field, Thales is currently developing a mobile version of this solution, with the support of Expleo, to make it readily available on military bases. This version is scheduled to be ready for use by summer 2023.

Laurent Fiorio, Global Head of Defence at Expleo, said: “The technology we are implementing with Thales not only guarantees the comfort of pilots but ensures the perfect fit needed for the successful operation of a helmet’s advanced functions. This shows that we have the skills to be a leading partner for transformation initiatives in the defence sector. Together, with our partners, we will continue to push boundaries.

This project was secured by the Expleo-Ausy consortium which is now one of Thales’ “Platinum” suppliers, the highest level of referencing possible according to Thales’ supplier policy covering Project Management Assistance, Quality, Electronics, Mechanics, Software and Systems services.

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