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Introduction: Aircrew equipment assemblies are life critical equipment worn by the aircrew to ensure protection from various life-threatening environmental conditions that may occur in nominal or off-nominal flight conditions. It is important for the sizing system of body worn aircrew equipment to be divided into different size classes such that it is as representative of existing groups in the population as feasible. Machine learning techniques provide a powerful tool to develop efficient sizing systems that are representative of actual body types existing in the population. The objective of the study was to use machine learning clustering techniques to identify naturally existing body types to formulate an optimal sizing system for an aircrew helmet. Material and Methods: The standard sizing schedule of an aircrew helmet using head length and head breadth was studied. An iterative semi-supervised machine learning protocol called K-means clustering was used to identify naturally occurring clusters of head types within the population. The cluster boundaries were identified to develop the final sizing schedule. Analysis of variance (ANOVA) with post hoc analysis was carried out on the four head lengths and head breadths. Results: Four clusters of head type were identified using K-means clustering. This led to a sizing schedule which can be descriptively called “Short-Narrow,” “Short-Broad,” “Long-Narrow,” “Long-Broad.” ANOVA showed a statistically significant difference between the four clusters for both head length and head breadth. Conclusion: Consideration of several variables in sizing schedules often fails to meet desired fitment. Standard sizing methods use linear partitions on individual control parameters. In reality, the proportional variation between parameters is not linear. Machine learning tools help in identification of naturally occurring clusters within the database considering several variables at the same time. This study uses machine learning techniques to identify existing groups in a population and develop a final sizing schedule. Similar analysis for other aircrew equipment assemblies can be carried out to determine sizing schedules which assist in design and fitment.

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