Camouflage design and head measurement

characteristic of Indonesian armoured

vehicle helmet
Cite as: AIP Conference Proceedings 1788, 030075 (2017); https://doi.org/10.1063/1.4968328
Published Online: 03 January 2017

Yukhi Mustaqim Kusuma Sya’bana, and K. H. Sanjaya

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 Camouflage Design and Head Measurement Characteristic
of Indonesian Armoured Vehicle Helmet

Yukhi Mustaqim Kusuma Sya’bana1, a) and K.H. Sanjaya1, b)

1
Research Centre for Electrical Power and Mechatronics, Indonesian Institute of Science
(RCEPM-LIPI), Bandung, Indonesia
a)
Corresponding author: yukh001@lipi.go.id
b)
kade001@lipi.go.id

Abstract. In this paper discussed camouflage design helmet for armored vehicles with comparing head measurement of
Indonesian anthropometric. Design process conduct with considering of design aspects involves function, materials,
operational, technology, user, and appearance (camouflage). As an application of Indonesian National Army that
qualifies factors needs: safety, comfort, practical and service. MIL-H-44099A Military Specification : Helmet, Ground
Troops And Parachutists is minimum limitation standard of military helmet production. Head measurement for product
design process guide is presented. Model simulation and helmet measurement using the design for ego and design for
more types ergonomics concept. Appearance shape concept is engaging camouflage towards background and
environment to deceive enemy viewpoint. Helmet prototype has tested ergonomically to an Indonesian National Army
soldier and stated that the helmet size is a comfort and fitted on the head when in use.

INTRODUCTION
War helmet has been used for centuries, from the time of the Sumerians, Assyrians, ancient Greek, and Roman.
Up the time of WWI (World War I) and WWII soldiers use a helmet made of steel [1]. Ancient thought that military
helmet must be resistant to various types of various types of assaults, penetration distances involve helmet made
from iron/steel impacting helmet very heavy weights. Combat helmet users will feel less comfortable and reduce
agility in the move[2]. The Strong and the heavy material has an advantage would not be penetrated by the
projectile, however the new viewpoint on the penetration of munitions and short-range assault small possibility,
even if it happens possibility will occur neck injury or bullet ricochets risk. Moreover, the steel helmet has a material
that is easily detected by radar and easily influenced into cold or hot climates [3].
In the early 1960s developed the technology is more lightweight and comfortable [1]. Therefor helmet priority to
protect the head from level II protection specifically resistant from beating, bump, collision from sharp, hard object,
and shrapnel. Accordingly, a helmet made from KEVLAR Aramid and epoxy resin that lighter than steel [1].
Material changes from metal in WWI, WWII into composite kevlar is PASGT (Personnel Armor System for Ground
Troops) and the MICH (Modular Integrated Communications Helmet) for SOF (Special Operations Force).
This research was motivated by the Army Cavalry soldier complaints about the size of the helmet used today; the
current helmet is imported item which is considered incompatible with the specifications of Indonesia [4]. Besides
the huge risk when soldiers must perform their duties, especially during reconnaissance out of the roof of an
armored vehicle and be targeted by enemy snipers.

International Conference on Engineering, Science and Nanotechnology 2016 (ICESNANO 2016)

AIP Conf. Proc. 1788, 030075-1–030075-8; doi: 10.1063/1.4968328
Published by AIP Publishing. 978-0-7354-1452-5/$30.00

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 Communication helmet should be able to accommodate the head size and needs of the Cavalry Army in its
mission. Sometimes they had to shoot enemies with weapons that exist outside. Therefore, the helmet should be able
to protect the vital parts of the head [5]. The important factor to be a concern is that helmet should fit into an
Indonesian cavalry heads, the identity shape, and function. In this study will be designed through camouflage
appearance. The purpose this study is to design and create a military helmet that comfortable and could support
communication activities while reducing the worst possible when there shrapnel or ricochets although there is armor
protection in the vehicle. Design process conducted in several stages begin from literature review to making the
prototype as shown in Fig. 1.

FIGURE 1. Armoured vehicle helmet design research process chart.

The concept in designing the helmet starts from the analysis of several aspects that will affect consideration in
deciding the design [6]. For consider issues besides user and appearance aspects are the function, materials,
operations, and technology.
Functional design is a design that includes aspects of usability and performance, improvement of sustainable
products requires the same emphasis on product and process design [7]. Form Follow Function (FFF) that form
follows function, which means not only the design of the design view only, but there was something behind it that
allows users to use the product [8]. Function aspect this helmet is supporting activities to communicate in armored
vehicles to protect the vital organs in the head with a protection level II, which is resistant to beating, bump,
collision from sharp, hard object, and shrapnel [9].
The primary material used to satisfy the specifications of military helmets are KEVLAR Aramid. Strength
polymer fibers have been proven through the test results using the FN handgun firing at a distance of 5 meters to 14
sheets of KEVLAR material. The results show that Kevlar can withstand attacks jacketed projectile with a 9mm
bullet full- the speed of 358 m/s [10]. Modern composite materials for KEVLAR fiber using thermosetting plastics
are epoxy resins. Lighter, reduce ricochets, not detected by radar, good insulation against noise opponents, free of
radioactive materials at high temperatures (when compared to a helmet made of polyethylene), not flammable and
can extinguish the fire themselves, are not affected climate, has a good power protection, and recyclable.
Operational adapted to the circumstances that are typical of the armored vehicle interior and the comfort level is
different from the other vehicles. Armored vehicles have a main aspect to protect passengers from military attacks,
the interior of armored vehicles was not as comfortable as commercial vehicles. Configuration is designed for easy
operation and maintenance of this communication helmet. The designs are designed need well adapted to the habits
of communicating and using Google or binoculars that exist in armored vehicles.
The helmet is used when troops Cavalry Army on a mission using armored vehicles, including driver, gunner
and commander. Helmet operational priorities for convenience and habits of forces when used during combat
vehicles inside or out, with an indefinite period and a maximum 24 hours. Meanwhile, when outside the vehicle,
there will be noise and disruption in the eyes due to dust, wind and light, therefore, require additional Google or
glasses.
The product that designed is armoured communication helmet for cavalry troops army. Therefore
communication devices using of analog systems with HF / VHF frequency are intended to be more difficult to trace
by opposite compared with Bluetooth or wireless devices. In order this function optimally, the design should
consider the main components of the communication helmet. Pre-Amplifier processing or signal processing

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electronics before entering into amps, PTT (push to talk) button to activate the microphone when you speak and the
other as a communication system supporting communication.

EXPERIMENTAL METHOD

Participants Measuring
User aspects study concerned with understanding the aspects of ergonomics is the study of a variety of human
problems in adapting to their environment, the knowledge that seeks to adapt to work conditions [5]. It has found
two discrepancies in data from studies in the literature that conducted, therefore need to be clarified. Participants for
this study were randomly selected from Indonesia, all selected subjects were normal physical health and were active
in their society. Participants are ten people selected randomly from age 20 to 38 with weight from 45kg to 78kg.

TABLE 1. Characteristics of participants

% stature with
Mean age % stature with % stature with
Weight (kg) Stature (cm) head
head length head breadth
circumference
32,6 ± 4,42 66,9 ± 12,81 168,6 ± 5,84 10,56 9,15 32,9

FIGURE 2. 1. Head length 2. Head breadth 3. Head circumference [17]

1. Head length: The maximum distance from the mid-sagittal point between the brow ridges (glabella) to the back
of the head.
2. Head breadth: The maximum horizontal breadth of the head above the ears.
3. Head circumference: The maximum circumference of the head above the brow ridges and ears.
S.D.: Standard Deviation

The design is conducted using of Design for Ego meaning designers only see the size of himself and assume that
the size is enough for others.[11] After prototypes were tested, the mass production of this helmet using Design for
more types that each user has the size of each as from size S to XXL [11].

Design Format Analysis (DFA)

Appearance aspects conduct with camouflage concept, camouflage Figureure means one or more Figureures or a
hidden form not seen in a while. Ability to hiding or delay perceptions depends on the effectiveness of camouflage
image [12]. Camouflage is designed to outwit two types of enemies, who watched from the ground and from the air.

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Camouflage depends on the effectiveness of the helmet design toward to the background of the surrounding
environment, in this environment gunner or a shooter is on top of armored vehicles.

FIGURE 3. Design format analysis outlines shapes of the vehicle as a reference in exploring the concept of camouflage
background environment of a helmet that will be designed

The Helmet shape has a dominant curved outline shape that contrast between the product and the surrounding
environment. Therefore, as much as the possible use straight line to design the helmet. To reduce the effect of light
reflection then used the non-gloss paint, or use a helmet and nets made with a coarse texture.The study of forms
through design format analysis approaches showed that the armored vehicle 1 and 2 is a powerful aspect about the
form of creating a helmet, while the D form is accepted line specifically with the biggest points.

Design Product
After analysis of design aspects phase that generates criteria or limitation of each of these aspects, the study
continued into the designing phase, as a way to get the approach of design decisions which include some direct
studies including simulation study, the configuration of components, models study, and sketches studies. Simulation
studies that conducted are one of cavalry army troop roles is as a gunner or a shooter because the position is often
performed when conducting outside activities on the armored vehicles and a bigger risk than the driver or
commander. Activity as a gunner is to shoot the enemy from the outlet hole where weapons were outside; some
positions were made include: sitting, half-squatting and standing. Activities that relate directly to the helmet is
receiving orders from the commander and driver coordination through earphones, get a visual through Google and
reported the situation through a microphone. Noteworthy here is that when the gunner outside or partially visible it
is expected that the helmet shape and color can be camouflaged when seen from a long distance. Configuration
components study helmet for armored vehicles is manufactured on a modular basis [13] consisting of the helmet
outside parts, liner (part of shock absorbers made of foam wrapped in cloth), and communication devices.
Consideration in designing helmets including comfort, use, and maintenance, the configuration is liner and
communication tools into one piece and must able for treatment such as washable and detachable, as well shell is
also easily detachable when it is not required.

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 Sketch design process is a continuation of the process determining a design limitation that has been done on the
points design aspect above. Sketch studies performed of the concept sketches, visual thinking, sketches gradually
and the process of observation sketch. This is different from the artist who sketched the objects in front of the eyes
directly [14]. Visual interpretation and speed in interpreting into a sketch of someone are different [15]. Therefore it
needs intervene management on a design team. Sketch of the idea of some experiments manually is selected and
then made digital thumbnail sketches of several alternative designs.

Modelling Study
Modeling study of the model is 1: 1 scale model, intended to interpret a display form from sketches that have
been conducted. Mock-up made of styrofoam is quite simple and relatively easier, aimed to approach the actual
shape and to eliminate miss perception of 2D objects into 3D models. Furthermore, will be made to function as a
prototype as shown in Fig. 4.

FIGURE 4. 1:1 Modeling study.

RESULTS AND DISCUSSION

Anthropometric Dimension
The anthropometric data of heads dimension were measured refer to Fig. 2 as shown in Table 2 there were
significant differences between Table.3 and Table 4. And the results is Table.3 is the closest data. Accordingly, it is
very necessary for the designers to take these findings into consideration while designing the product that related to
the Indonesian head measurement.

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 TABLE 2. Values of different percentiles for head dimension (cm).

Percentile 1 2 3
1st 17,045 14,09 54
2,5th 17,1125 14,225 54
5 th 17,225 14,45 54
10 th 17,45 14,9 54
50 th 18 16 56,5
90 th 18,5 16,55 57,1
95 th 18,5 16,775 57,55
97,5 18,43 16,43 57
99 th 18,47 16 57
100 th 18,5 16 57
S.D. 0,46 0,82 1,4

TABLE 3. The anthropometric of Indonesian heads data from interpolation of data pheasant (1986), Suma'mur (1989), and
Nurmianto (1991) [5].

Percentile 1 2
5 th 17,23 14,45
50 th 18 16
95 th 18,5 16,78
S.D. 6 5

TABLE 4. Heads anthropometric in the center of military exercises basic education KOBANGDIKAL [4].

Percentile 1 2 3
1st 14,06 11,05 52,7
2,5th 14,4 11,35 52,71
5 th 14,69 11,61 53,4
10 th 15,02 11,91 53,41
50 th 16,2 12,96 55,1
90 th 17,37 14,01 56,42
95 th 17,71 14,31 56,8
97,5 17,99 14,57 57,12
99 th 18,33 14,87 57,49
S.D. 16,20 12,96 55,10

The design process of armored vehicle communication helmet after conducting a simulation study,
configuration, models, and sketches, generate a final design decision. Accordance systematics research in Fig. 1, if it
is less appropriate design decisions so must pull back to the previous product design process. Implementation of
design is using digital modeling techniques to facilitate and accelerate progress compared to the manual modeling.

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 Digital Modelling
Making the digital model is the last process that serves to communicate from sketches and measurements into a
real model. Modeling, drawings, and 3D Rendering of a helmet use program Rhinoceros 5.0 (Robert McNeel and
Associates, USA). Drawing that has been processed by rendering is a scene process of building a 3D model can be
geometry, viewpoint, texture, lighting, and shadow information as a description of the virtual scene. To see the 3D
shape of the helmet, the color, and texture in digital simulation. Process simulation approach can bridge and reduce
the risk of errors in the designing process of helmet prototyping. Comprehension of the viewpoint of an image is
various, depending on the ability someone to visualize. Perspective draw that has processed by rendering is to clarify
and reduce errors in 3D visual perception is conducted shown in Fig. 5.

(a) Front, side, and top view (b) Perspective view

FIGURE 5. Digital 3D rendering.

Prototyping
The result from the design draft is a prototype that became the initial form as a reference to be reviewed, to be
developed and manufactured in accordance with the requirements. The prototype was used directly tested in real
conditions in user with armored vehicles. Helmets have been made, used by a cavalryman as commander is tasked to
coordinate in armored vehicles. The helmet prototype was also tested with the situation by the gunner to stalking and
camouflaged with its surrounding environment of armored vehicles as shown in Fig. 6.

(a) Displayed on a (b) used by the commander in an armored (c) used by gunner during reconnaissance.
mannequin. vehicle
FIGURE 6. Results of the camouflaged armored helmet used by gunner during reconnaissance.

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 CONCLUSION
In this research has been done design helmet communication by the needs of the cavalry of the army that the
dimensions, shape, and weight. The elements of strength and safety fulfilled by using material KEVLAR Aramid
according to the standard MIL-C-44050A on the detailed specifications of military cloth, ballistic and aramid
whereas there refers to the standard MIL-H-44099A Military Specification: Helmet, Ground Troops, and
Parachutists.
The previous helmet not suitable because it’s imported from Germany with different standard sizes with
Indonesian. The prototype helmet has been tested cavalry soldier, and the result is a positive response from users,
stated that the size of the helmet comfort and fit on the head when in use. The stage that remains to do is to test the
strength of the method of inspection based on standards (MIL-H-44099A Military Specification: Helmet, Ground
Troops And Parachutists 1986), as well need to test the effectiveness of camouflage helmet design in delaying the
psychological perception.

ACKNOWLEDGEMENTS
I would like to thank all the participants for their patience during collecting the measurement. Special thanks are
also to my University (Institut National of Technology), Research Center for Electrical Power and Mechatronics
(RCEPM LIPI) , Indonesian Cavalry AD, LEN industry, Cavalry Army Education Center, for their support.

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