Galvion CORTEX
Skills Used: Industrial Design, User Research, Form Development, Visual Branding, 3D Printing, SolidWorks, SketchBook Pro, Photoshop, Keyshot
CORTEX is an advanced, intelligent headborne system that provides processing, power management, and data connectivity, enhancing warfighter effectiveness on the ever-evolving battlefield. I served as the lead industrial designer, collaborating with various engineering resources to bring the CORTEX system to operators. My primary contributions included the design of the housing and exterior mechanisms for the Head Compute Module, Battery Pack, Sensor Interface Module, Rails, Keypad, and VAS connector.
Product Requirements
01: Helmet Agnostic
Newer safety features have been developed since the release of the original MESA car seat. The scope of the project required these features to be added into the new base along with findings from crash simulation.
02: Open Architecture
Certain surfaces of the base were fixed in place to maintain the relationship between the base and child carrier. In-addition it was fundamental to keep certain locking, rotation and mounting locations in there required areas.
03: Durability
UPPAbaby products incorporate the use of primary shapes with soft rounded edges and angles in the architecture of the product. It was necessary to include these design details into the MESA Max.
Baseline Geometry
Fixed Product Architecture
Load Leg: A load leg was added to the MESA Max base. The load leg pivot point location, angle and height were locked into place.
Mounting Locations: The mounting rods needed to stay in their fixed locations in order to remain compatibility with the carrier.
Carrier Surface: The height of the top surface had to stay in place to keep the compatibility with the carrier and to maintain safe crash performance.
Anti-Rebound Bar: A rebound bar was added to the base. The height, angle and location of the ARB was fixed in place to optimize crash performance.
H.C.M. (Head Compute Module)
The H.C.M. (Helmet Compute Module) is the primary computation unit of the CORTEX platform. It processes data from various digital inputs, including strobes, sensors, drones, and weapon sights, and displays this information on a heads-up display or through night vision goggles. The H.C.M. consists of a two-board PCB assembly and a backup battery. Additionally, the housing design was engineered to be compatible with sixteen different helmet models.
Adjustable wings were designed into the RCM to allow for interchangeability with different helmet shell platforms and sizes. The wings telescope using a worm gear mechanism.
Adjustable Wings
3-Mode Swith
A 3-mode switch was designed to enable three different operating modes. On, off, and silent mode. The switch is indexed and aligned along a vertical axis, allowing for blind mode switching while the helmet is on the operator's head during missions.
R.H.M.B. (Rear Head Mounted Battery)
The Rear Head Mounted Battery (R.H.M.B.) serves as the primary power source for the CORTEX platform. It powers the sensors, strobes, heads-up display, and night vision goggles. The R.H.M.B. contains two pouch battery cells, a PCB, and electrical contacts. The exterior features include a release lever, a battery level indicator, and snag guards.
Snag Guard
The shape of the ARB mimics the shape of a vehicle headrest to signify the correct positioning. The design also incorporates a "reverse waterfall" in the negative surface to break up the large area and follows the UPPAbaby VBL.
Battery Level Indicator
The battery pack release lever has two purposes. It releases the battery pack from the H.C.M. and acts as a mechanical actuator for the battery level indicator. To activate the indicator, the battery must be removed from the H.C.M. and pressed down for three seconds. This design helps prevent light emission during night operations.
Helmet Rails
The Rear Head Mounted Battery (R.H.M.B.) serves as the primary power source for the CORTEX platform. It powers the sensors, strobes, heads-up display, and night vision goggles. The R.H.M.B. contains two pouch battery cells, a PCB, and electrical contacts. The exterior features include a release lever, a battery level indicator, and snag guards.
Ambidextrous Peripherals
The shape of the ARB mimics the shape of a vehicle headrest to signify the correct positioning. The design also incorporates a "reverse waterfall" in the negative surface to break up the large area and follows the UPPAbaby VBL.
Tie-Down Locations
Tie-down locations were integrated into the rails to allow a 1" nylon strap to pass through and anchor accessories, such as strobes and sensors, during regular use and skydiving.
Keypad
The Rear Head Mounted Battery (R.H.M.B.) serves as the primary power source for the CORTEX platform. It powers the sensors, strobes, heads-up display, and night vision goggles. The R.H.M.B. contains two pouch battery cells, a PCB, and electrical contacts. The exterior features include a release lever, a battery level indicator, and snag guards.
Keypad Alignment
The keypad is closely aligned with the Frankfort plane, allowing the operator to easily navigate and identify specific buttons while wearing a helmet. The Frankfort plane is defined as the horizontal plane that spans from the bottom of the eye socket to the top of the ear canal. This alignment is significant because it establishes a subconscious mind-muscle connection that helps the operator locate the keypad more effectively.
V.A.S. (Visual Augmentation System) Connector
The Rear Head Mounted Battery (R.H.M.B.) serves as the primary power source for the CORTEX platform. It powers the sensors, strobes, heads-up display, and night vision goggles. The R.H.M.B. contains two pouch battery cells, a PCB, and electrical contacts. The exterior features include a release lever, a battery level indicator, and snag guards.
Protective Bezel
The shape of the ARB mimics the shape of a vehicle headrest to signify the correct positioning. The design also incorporates a "reverse waterfall" in the negative surface to break up the large area and follows the UPPAbaby VBL.
S.I.M. (Sensor Interface Module)
The Rear Head Mounted Battery (R.H.M.B.) serves as the primary power source for the CORTEX platform. It powers the sensors, strobes, heads-up display, and night vision goggles. The R.H.M.B. contains two pouch battery cells, a PCB, and electrical contacts. The exterior features include a release lever, a battery level indicator, and snag guards.
Tie-Down Location
Tie-down locations are molded into the base of the sensor interface module, allowing for a 1" hook and loop strap to secure the housing in place during regular use and skydiving.
