As you might imagine, military scuba rebreather units are hard to come by... especially if you need 3 of them on short notice. ARROW Props knew they'd have to be custom built and chose us for the assignment.
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Concept Reference
We were provided with a couple of small, low-res images to convey the layout, components, and design language of the units. Later, better images were obtained that helped to clarify the concept.
 Production Provided Reference |  Online Reference |
Design Process
Little contextual information was provided as to how these units were to be used. At the very least, they would have to be built to withstand rough handling and exposure to salt water.
As is often the case, we were directed to provide a couple of choices of "found-objects " that could serve as the basis for the design. The item chosen, ended up being a car battery-booster unit.
It was a terrific find, as it had many useful attributes, including suitable size/proportions, color, and a robust construction, Looking a little more "high-tech" than the real thing also helped... as that was ARROW's usual design bias.
A mock-up of the device showed great promise, and was quickly approved.
As is often the case, we were directed to provide a couple of choices of "found-objects " that could serve as the basis for the design. The item chosen, ended up being a car battery-booster unit.
It was a terrific find, as it had many useful attributes, including suitable size/proportions, color, and a robust construction, Looking a little more "high-tech" than the real thing also helped... as that was ARROW's usual design bias.
A mock-up of the device showed great promise, and was quickly approved.
 Selected "Found-Object" |  Rough Concept Rendering |
Typical of mass produced housings, this example was made of ABS plastic. This meant that it could be easily cut, drilled, and painted. It would also be structurally sound enough to accommodate the attachment of certain requisite components, like the breathing hoses and air tank.
 Design Mockup (tank unmounted) |  Tank Mounted & Plumbed-In |
A prototype unit was quickly produced in order to see how it would integrate into the rest of the gear the stunt divers would be wearing. Other than having to change-out some fasteners from plated to stainless steel, and providing a properly captioned cover for the control panel,
the prototype was virtually a finished unit.
the prototype was virtually a finished unit.
Test Fitting
As the stunt divers needed a functional air supply, the rebreathers hoses could not actually attached to the breathing mouthpiece (as it normally would be). These were instead, dressed into openings on the cover that enclosed the divers real air supply (located in his backpack).
With the real breathing hoses coming out of the same cover, it appeared as though the rebreather hoses simply go into, then out of, the diver's backpack. Not the way it's really done of course, but a cheat that most observers would never even notice.
With the real breathing hoses coming out of the same cover, it appeared as though the rebreather hoses simply go into, then out of, the diver's backpack. Not the way it's really done of course, but a cheat that most observers would never even notice.
Construction Process
Construction was very straight forward. In fact, the only significant issue to resolve was finding a method for securely attaching the breathing hoses. Luckily, after removing the unwanted device handle, it was discovered that the breathing hoses fit perfectly over the remaining cylindrical projections. All that was needed, was some kind of barbed component that would engage the convolution inside the end of the hose.
The barbed component itself was simple to make; consisting of an assembly of stainless steel washers, nuts, and a carriage bolt. Some unwanted internal structure (where the device handle had been previously mounted) needed to be cut away to accommodate mounting of the barbed components... but this was easily accomplished.
The finishing touch, was the inclusion of a custom control panel cover. These were produced by a local sign making company, and were made from CNC cut, black-anodized, brushed-aluminum sheet.
The captions were rendered via a laser process, and appear light grey in color. Naturally, these panel covers would be impervious to salt water.
The barbed component itself was simple to make; consisting of an assembly of stainless steel washers, nuts, and a carriage bolt. Some unwanted internal structure (where the device handle had been previously mounted) needed to be cut away to accommodate mounting of the barbed components... but this was easily accomplished.
The finishing touch, was the inclusion of a custom control panel cover. These were produced by a local sign making company, and were made from CNC cut, black-anodized, brushed-aluminum sheet.
The captions were rendered via a laser process, and appear light grey in color. Naturally, these panel covers would be impervious to salt water.
Completed Rebreather Units
This project's success, was largely due to the availability of a well suited "found-object" that exhibited a great deal of useful attributes.
Experience has taught us to adopt this method whenever possible, as this can provide sophisticated design, with robust construction, without incurring the lengthy build-time and the high cost normally associated with building from scratch.
Experience has taught us to adopt this method whenever possible, as this can provide sophisticated design, with robust construction, without incurring the lengthy build-time and the high cost normally associated with building from scratch.