Master thesis|2018|20 weeks|Collaboration with FLIR Systems

A new welding helmet vision utilizing mixed reality and thermal imaging solutions to enable precise welds that meet the high industry standards

Project goal

How might we provide welders with correct parameters to meet a desired weld result?

Improve vision
For the welders while welding, increasing their precision and safety

Assist welding
Through guidance and knowledge instantly available

Improve quality
Through temperature and heat distribution overview

Be part of welder
Should feel like a natural part of the welders and their work flow

Process snapshots

Snapshots of research, user observations, workshops, personas, mood boards, prototyping, sketching, 3D modeling, evaluation with users and model making.

Understanding the user

Understanding the welders and their needs to further develop the design direction was crucial. Welders are very proud of their work and want this to reflect in the gear they use. The product was designed to primarily attract the younger generation of welders who are used to connected and smart products.

Sketch exploration

Sketches were produced in several rounds of iterations, in parallel with cad models and mock-ups to both find a design language that would fit Flir in this completely new context as well as refining the functional elements of the product.

A day with Flir Vision

This storyboard shows a normal day of a welder working on highly complex welds in a shipyard setting. It explains how and when in the process Flir Vision enhances the welders’ workflow. Flir Vision allows for easy access to weld parameters and instructions, material temperature overview, welding speed overlay and provides a clear vision.

Flir Vision

A new welding helmet vision utilizing mixed reality and thermal imaging solutions to enable precise welds.

Passive mode

Mask easily pivots from active to passive mode. Flame retardant hood can easily be opened and closed with the Velcro strap.

Head strap

The head strap enables the welder to fit the mask according to his or her needs. The main adjustment wheel can be tweaked from the outside of the flame retardant fabric.

Protective visor

The outer visor protects the curved auto darkening lens behind it. With the push of two buttons it is easy to exchange when worn down.

Air channels

Filtered and cooled air flows through integrated air channels from the powered air unit connection hose into the mask.

8 hour battery

The battery is easily exchanged on the back of the flame retardant fabric. Lasts for a full day of welding.

Infrared camera

Produces an infrared projected overlay allowing welders to see better than ever before. The camera constantly measures the temperature of the material and the weld, enabling welds to live up to the tough industry standards.

Physical UI wheel

The bridge between the welder and the heads-up user interface. The simple wheel is rotated to navigate through the interface, and pushed to confirm actions or held to return to the main screen.

Heads up interface

FLIR Visions UI provides instant access to job parameters and weld specifications. Utilizing infrared technology provides instant feedback and allows welders to stay within the right temperature range throughout weld procedures.

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