When the Department of Defense decided that their previous landscape flight simulators used to train pilots required too large of a display, too large of an enclosure space, and were starting to feel a bit antiquated in general, they went on the lookout for a helmet –mounted simulation solution to replace the traditional rear-projection screens they were using. This case study explains the design challenges associated with developing the new AHMD (Advanced Helmet Mount Display) and how Zygo was able to overcome them through their expertise in optical design and assembly.