Rapid prototyping for the JLTV turret cover.
A customer received new JLTVs equipped with turrets that needed covers asap to prevent potential water intrusion. The vehicles are full of electronics which are particularly vulnerable to corrosion - the kind of corrosion that often goes unnoticed until there are electronic failures (see our blog post from 10/13/20).
They contacted Cocoon to fast-track a custom turret cover. We quickly put two people on site who began a rapid development process which included:
An initial working session with the customer to explore issues, identify challenges, and brainstorm on ideal solutions.
Point-to-point 3D scanning to build a wireframe of the turret in order to view it from different angles and understand how to work with its challenging shape.
Building a 3D solid computer model from the wireframe to use in developing a cover pattern.
Video sessions with Cocoon team members in different locations to troubleshoot, problem-solve, and collaborate. (The unique configuration of the turret made drainage particularly challenging.)
Creating a beta cover that could be used for an initial test fit. (Because of the need for speed, we used the actual cover material for the beta rather than a patterning material.)
Gathering customer feedback during the initial fit regarding form, fit, and function, and collaborating on how to refine the cover design, strapping, attachment points, etc.
(This was all accomplished in just a week)
The next step was to incorporate the various refinements and build a modified prototype for a second fit.
Fortunately the second fit went so well that we didn’t need to do any additional modifications and were able to move right into production.
Within 7 weeks of receiving a formal order we shipped the first batch of completely customized covers to the customer.
Certainly technology was an important part of the process, but the real keys to success were a highly collaborative customer, open communication, and deep experience in cover design and production.
Side Note: During the brainstorming sessions we learned that turrets pointing different ways make storage more difficult. While not part of the original brief, the customer decided to use the cover design to standardize the stow configuration by designing the covers so they could only go on when the turret was pointing forward.