Revision’s Batlskin Caiman Special Operations Forces Helmet Suite: Accelerated Iterative Design and Direct User Collaboration

Revision’s Skeletonized, Scalable SOF Head Protection Solution

Revision’s Batlskin Caiman Helmet System suite, unveiled at SOFIC in May 2017, is a unique multipurpose helmet line that breaks new ground in the rapidly-advancing special operations helmet industry. The Caiman suite consists of a conformal hybrid helmet system, a ballistic helmet system, and a bump helmet system, all of which have been engineered to quickly and efficiently adapt to mission requirements. To realize this forward-thinking vision, Revision enlisted the assistance of Special Operations Forces (SOF) users, banking on their vast, diverse in-the-field experience and incorporating their feedback throughout the thorough-yet-fast-paced development process. 

As is typical for Revision, this development process was taken to the extreme: Revision set ambitious goals for performance and innovation, brought a wide-range of SOF contacts and allies to the table, worked within a narrow timeline, and built these helmet systems from the ground up. The end result of a year-plus of design, development, and extensive review and testing is an immensely versatile, cutting-edge suite: Revision’s Batlskin Caiman helmets are engineered for full-spectrum use, providing elite protection and performance across coastal marine, riverine, maritime, high-altitude, and ground maneuvers. Revision has also developed a new set of Caiman accessories specially-designed to enhance this scalable helmet systems for boat, vehicle, and HALO/HAHO, as well as mountain, river, and direct action operations. The skeletonization of all system components has significantly reduced the overall weight, and the neck load burden, compared to currently fielded helmet systems, and emphasizes scalability and mission-specific accessories for highly dynamic operations. Revision’s Caiman Hybrid Helmet is particularly unconventional in that can be ballistically-enabled—add-on armor appliques attach to the top, front, and back for ballistic, blunt-force, blast-force, and fragmentation protection.

Above: Revision’s Batlskin Caiman Head System suite —a Ballistic System (left), a Hybrid System (middle), and a Hybrid System with Ballistic Applique— are lightweight and scalable, and are tailored for the intense demands of Special Operations missions.

Being a scalable, highly adaptable solution, the Caiman Head Systems support use by Green Berets, Navy SEALs, MARSOC (Marine Special Operations), the Ranger Regiment, Air Force Special Operations (AFSOC), PJs (Pararescue Jumpers), Combat Controllers, and SWCC (Special Warfare Combatant-Craft Crewman) Coxswain, among others. The system is optimized for use across the global spectrum of special operations forces—humanitarian assistance and peacekeeping, counter-terrorism and counterinsurgency, low-intensity conflict and full-scale war, military freefall, maritime interdiction, combat swimming operations, search and seizure, and long range patrol (maritime and ground platforms)—and across a wide range of extreme and volatile conditions—day or night, tropic or arctic, arid desert or open ocean, points in-between, and beyond. Beyond these SOF applications, the resourcefulness of Caiman head systems also makes them ideal for any international forces—law enforcement, paramilitary, peacekeeping, and beyond—seeking this unique combination of agility, protection, and scalability. This new head system, built from scratch and tailored to the feedback of SOF users, epitomizes Revision’s forward-thinking, holistic-rather-than-triage approach.

Above: Revision’s Batlskin Caiman Head System suite includes a variety of accessories including two visor variations (left – fixed arm, right – NVG arm) and two mandible guards (left – ballistic mandible guard, right – bump mandible guard).

The Unique and Influential Genesis of Revision’s Caiman Helmet Suite

A singular and complex undertaking such as the Caiman helmet development project was truly cross-functional, with numerous moving parts, phases, and iterations before a final product was reached. While this in itself is not unusual for a high-profile Revision project, the development of Caiman was unique in its speed and the scope of involvement. This program set a particularly fast pace as compared to high-value undertakings from years past. And, Revision called upon a considerable network of SOF contacts and connections, amassed throughout years of interacting and building relationships with this crucial community. A select cohort of active duty operators and former service members provided vital feedback throughout the development process in the first-half of 2016, shedding light on how best to tackle and target each innovation challenge, and helping guide and refine Revision’s solutions at each stage.

Revision’s energized and strengthened manufacturing capabilities also factored heavily into the development of the Caiman suite. Since 2013, Revision’s Newport, Vermont facility—Revision’s primary helmet manufacturing hub—has expanded by 16,000 sq. ft., and the number of employees that work at this facility has more than doubled. In parallel, Revision has made substantial investments in new molding presses, added preform presses, increased chilling capacity, new molds, and increased cutting capacity. This supports an increase in overall polyethylene manufacturing capacity. In the last few years alone, Revision has successfully delivered on significant contracts for UHMWPE products with both U.S. Military and international customers.

Above: A Batlskin Caiman helmet is assembled in Revision’s Newport, Vermont facility. 

The design, development, and project management teams also took full advantage of Revision’s significant rapid prototyping capabilities. This allowed Revision to quickly produce, analyze, and hone designs and prototypes, and feed these updates to key contacts for feedback, ensuring the direction of the Caiman development path perfectly aligned with the specific needs of operators, especially those engaged in extreme, unstable missions. Revision looked at this as a fantastic opportunity to collaborate with users directly, getting full-size prototypes in their hands, delivering sketches, videos, and ideas, and receiving immediate feedback. The end-result truly reflects this intensive, collaborative effort.  

A Focus on User Feedback and the Demands of Special Operators in the Field

Every aspect of the suite was scrutinized and trialed, often with multiple ideas vying for inclusion, then weeded out upon review from users. Some components—such as the new mandible guard, with the ability to swing out; less rigid, open-cell comfort foam; and the five-size comfort fit—were improvised on-the-fly, stemming organically from the user responses the team received. The revamped helmet sizing is a particular highlight of this head system that will ensure that users have a comfortable and secure helmet for superior performance and protection. Five sizes (as opposed to the standard four) ensures users are wearing the smallest, lightest helmet that optimizes the fit/performance/comfort ratio. The Caiman development team zeroed-in on this change through comprehensive analysis of 3D printed prototyping and a database of head measurements. Through this improvement, the team projected that 40% of users would wear a lighter helmet than with a traditional four-size helmet. This is a prime example of how the development team got from point A to point B through a systematic progression of conception, designing, sketching, rapid-prototyping, and feeding this into the user feedback loop until it was perfected.

Revision has never been content to simply repurpose and repackage an existing product, so the Caiman program was taken as a challenge to think big and to realize the game-changing aspirations of the Company. The Caiman project management team put in a lot of legwork corresponding, Skype-ing, and meeting with key contacts and stakeholders, delivering schematic representations, videos, and prototypes, and absorbing direct, unfiltered feedback. This collaborative, iterative process allowed the team to wholly eliminate guesswork and address all head system functions in real time. Crucially, SOF users can feel real ownership of the end-product, knowing that their demands were addressed and readdressed continuously. This is not a head system created in a vacuum: The very real vision of users is alive in Revision's Caiman helmet suite, unmediated and undiluted.

Revision’s pioneering Batlskin Caiman Head Systems suite is an especially noteworthy development in terms of total head system integration. Caiman helmets are fundamentally different helmet solutions, emphasizing scalability and mission-specific accessories. Moreover, Caiman helmets are expressly designed to incorporate electronics, headsets, and other SOF equipment needs. Revision’s integrated systems approach has always been developed from the individual operator outwards and focused on human factors and operational outcomes. In Revision’s ongoing efforts to create the most effective, responsive equipment possible for troops in the field, the company is innovating from converging directions: creating helmet systems that are engineered to accommodate headborne gear and tactical headsets, and creating headborne accessories designed to work perfectly with the most advanced modern helmet systems. And, Revision’s lithium-ion Nerv Centr batteries and power management systems provide centralized power for a variety of fielded devices and headborne equipment.

Total Head System Integration with Revision’s SenSys ComCentr2 Tactical Headset

Revision’s background in integrated soldier systems—creating protective goggles, spectacles, and sunglasses; advanced helmet systems; and lithium-ion power management solutions—makes the company perfectly positioned to shake up the communications and hearing protection industry. Revision has worked in parallel with companies in this field, collaborating to seamlessly integrate helmet systems with tactical headsets and other headborne devices. Revision has assembled the relevant requirements and technologies to deliver a headset communications solution that delivers more capability, integrates more options, and drives expectations forward.

Leveraging the company’s unique capabilities and soldier systems vision, Revision introduces the SenSys ComCentr2 Tactical Headset System, a next-generation circumaural headset that enhances communication and awareness while also protecting users from from hazardous peak and steady-state noises. Revision’s ComCentr2 headset integrates perfectly with fielded helmets and eyewear, enhancing user protection and responsiveness. This tactical headset is optimized to work with a variety of helmet shapes and types. The ComCentr2 system is particularly calibrated to work seamlessly with the Caiman Head Systems suite, whether worn over-the-head or rail-mounted.

Above:  Revision’s new SenSys ComCentr2 Tactical Headset System is designed to integrate seamlessly with modern helmets and specifically Revision’s Caiman head systems.

In a field that has seen many half-measures, Revision has developed an efficient communications and hearing protection solution that provides the comfort and sophistication warfighters deserve: ANR technology mitigates low-frequency, steady-state noise, such as that generated by vehicles; two forward-facing and two rear-facing microphones provide high-fidelity 360° situational awareness; and 3D spatial communication separates radio net transmissions to improve speech intelligibility and reduce cognitive burden. The fully digital ComCentr2 platform is plug-and-play accessible and USB-compatible with devices and computers, and features upgradable software that eliminates product obsolescence. The system also features an intuitive, hand-held control unit—Human Interface Device (push-to-talk / PTT)—for quick, mid-mission switching between radios and volume adjustment. Unlike systems containing a fixed number of ports, the PTT can be outfitted with a custom dongle, accommodating a variety of mission-specific configurations for multi-radio and multi-channel environments. Revision’s innovative, configurable dongle system supports connectivity to multiple legacy connections, new radio connections, smartphones, intercoms, and, as C4I systems continue to evolve in the digital age, other newly introduced digital connectors yet to come. The modular design of the ComCentr2 system ensures continuous compatibility at a low total life cost. The SenSys ComCentr2 Tactical Headset System incorporates technological developments from the past decade-plus into a self-contained, integrated unit that facilitates enhanced situational awareness and improved command and control.

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