SBIR-STTR Award

The development of affordable, high performance hearing protection and communication systems is critical for USAF and DOD aircraft maintainers who must work in the vicinity of jet exhaust noise during launch and recovery operations. Aegisound is in a unique position to leverage recently completed first-generation ANR hearing protector designs, intended for operation in JSF noise fields, to investigate further design improvements for affordability and even higher performance. This Phase I proposal addresses a range of performance issues for the use of ANR earplugs in harsh noise environments. Earplug design, controller design, and actuator design all play vital roles in high noise attenuation. Speech intelligibility and resistance to electromagnetic interference are also included as critical system requirements. All of these components and design criteria will be evaluated for performance versus their respective roles toward affordability. During the Phase I program, all relevant design and production issues will be identified and summarized with respect to affordable procurement of hearing protection systems that are useful in 150 dB noise environments. A detailed analysis of design metrics, production alternatives, cost drivers, and a plan for deployment of the proposed solutions will be provided at the conclusion of this work.

Keywords:
Extreme Noise, Jet Noise, Hearing Protection, Speech Intelligibility, Active Noise Reduction, Affordability, Manufacturing

Aegisounds existing Digital Active Noise Reduction (DANR) HPD product configuration, developed under a prior Lockheed Martin JSF SDD program, represents the baseline hearing protector system for this SBIR project.  Affordability and performance requirements formed the basis for a Phase I investigation of the DANR HPD.  Key areas of Phase I investigation included the product cost, power consumption, and potential for higher levels of noise attenuation in higher ambient noise fields.  The Phase I effort identified specific improvements to implement during Phase II, to move the DANR HPD system closer to the target cost and performance metrics established by the solicitation. This subsequent Phase II program is designed to enact a series of critical tasks that target a nearly 35% unit cost reduction and improved manufacturability of the DANR HPD.  By applying SBIR resources toward developing lean manufacturing processes for the DANR HPD, optimizing labor efforts, improving and automating processes and test procedures, and revisiting aspects of the existing design for BOM and labor reduction, significant long term unit cost savings are expected, in even low volume production.  The military and commercial viability of the DANR HPD product will be dramatically improved by the work of this Phase II program.

Benefits:
There is a dramatic need for improved hearing protection and intelligible communications for aircraft maintainers in all branches of the DOD.  This Phase II program will aggressively seek cost reductions that lead to affordable procurements of new digital active noise reduction technologies in military qualified hearing protection and communications products.  Increased allowable exposure times for personnel in noise and improved mission effectiveness will be realized by the DANR HPD products at the conclusion of this program.  In addition, there will be collateral benefits to the cost and producibility of other custom earmold products (passive and communications earplugs) that are useful in a variety of military occupations.  Commercial sales opportunities for industrial noise control will also be enhanced by the expected product cost reductions resulting from this Phase II effort.  

Keywords:
Active Noise Reduction, Hearing Protection, Speech Intelligibility, Manufacturability, Cost Reduction, Extreme Noise