F-16 Dodecahedron Project Title: F-16 Dodecahedron Visual Display Dome Project Customer: United States Air Force / Lockheed Martin Information Systems was Prime Contractor.

United States Air Force F-16s

ACME SolidWorks™ Rendering of Dodecahedron Visual Display Structure (Figure F-1)

Project Overview: Because of other successful work for Lockheed Martin Information Systems (L-M), ACME was approached by L-M personnel from the Luke AFB simulation facility because of difficulties they were experiencing with a ground based partial dome (mini-dome). Subsequent to the contact, a design consulting contract was initiated by L-M whereby ACME mechanical design engineers would investigate and report on the installation and maintenance problems L-M was experiencing with the mini-dome. ACME sent a team of engineers to the Luke AFB site and conducted a thorough investigation into the existing design. Included in the investigation was the development of a 3-D model of the mini-dome so that finite element and modal analyses could be conducted. The analyses identified some fundamental design flaws in the dome. The design flaws were confirmed by comparing the actual dome vibration behavior with the modal analysis results.

ACME Services Used: Mechanical Engineering, Systems Engineering, Site Analysis Consulting, Fabrication of Initial Set of Projector and Mirror Mounts.

Project Details: L-M amended the analysis task to execute a detailed design of a new dome structure.   The dome utilizes 11 pentagonal shaped rear projection screens to provide a high-resolution scene for F-16 pilot training.  To minimize the required mini-dome volume, 8 of the visual channels require at least one fold mirror in the optical path.  ACME systems engineers conferred with the L-M engineers and reviewed 1) the optical analysis for each channel, 2) the vibration goals to minimize scene jitter, and 3) the dome equipment maintenance and installation strategies.  The latter two strategies are critical due to the projector-mirror-screen equipment combination for each of the 11 channels.  ACME system engineers also conducted an analysis to identify the projector adjustment tolerances needed to ensure that the projectors are properly positioned.     Once the mini-dome design tolerances were identified, ACME proceeded with the detailed dome design.  This design identified the dome structure, the screen attachment points, the fold mirror support structure, and the projector mounts.  Figure F-1 shows an overall view of the mini dome.

L-M engineers reviewed the design details and, in an effort to minimize external expenses because they had several domes to fabricate, decided that the 3-D models and detailed drawings were of sufficiently high quality that they would build the dome in-house.  This decision was also due to the fact that ACME utilized simple, commercially available construction materials.  The only areas with a high degree of design complexity were the projector mounts.  The projector mounts had to support the heavy RGB projectors, efficiently allow microscopic adjustment over a 2” span, be very stable, and low cost, as 11 of them are needed for each dome.  ACME fabricated the first set of projector and mirror mounts and forwarded them to L-M for use.  Figure F-2 shows the completed projector mounts.

Delivery Date: September, 2003

Customer Comments: N/A

F-16s Mirror Mounts (Figure F-2)