Additive Manufacturing Design of a Vibration Isolator for Rotorcraft Simulator Seats

Helicopter pilots are exposed to a wide range of vibration frequencies, primarily generated by engine and rotor dynamics. These vibrations, particularly within the 0.5–80 Hz range, pose significant risks to pilot health, including musculoskeletal injuries and fatigue. To mitigate these effects, vibration isolators are employed, with passive and active isolation systems offering different advantages. This study investigates the initial design and performance of a novel metal additive manufactured vibration isolator, optimized for placement under the pilot's seat in a rotorcraft simulator. The isolator was designed with key structural parameters including stiffness, coil dimensions, and material properties while maintaining a lightweight and durable form, with a primary goal of validating the additive manufacturing of a metallic isolator. Experimental corroboration was conducted by incorporating modifications to the Gannon Biomechanics Flight Simulator test stand (GBFS), comparing the novel isolator to an elastomeric isolator. Results demonstrate the successful fabrication of the initial additive isolator design. The additive isolator displayed a similar performance to the rubber isolator after being installed in the GBFS, though limitations on the current test rig and sensing configuration did not allow accurate characterization of the transmissibility. This research sets the groundwork for further development of a novel additive isolator and test facility.