ABOUT
ADVANCING LIGHTWEIGHT SOLUTIONS THROUGH INNOVATION
FPP Defense is a U.S. based company with advanced capabilities in research, development, and manufacturing, serving both the U.S. Defense and commercial markets. As a leader in lightweight military technologies, FPPD specializes in advanced armors, ammunitions and packaging systems.
FPP Defense is the defense division of Frontier Performance Polymers Corporation, founded by Jerry Chung in 2001. With two buildings in New Jersey, FPPD spans 60,000 sq ft of state-of-the-art research facilities, equipped with specialized machinery and laboratories designed specifically for the R&D and manufacturing of advanced polymer materials for DOD applications. Over 25 years, FPPD’s team of skilled engineers have been working to address some of its military partner’s top priorities of reducing the weight soldiers bear and improving their combat survivability. We are currently focused on developing, refining and fielding an innovative high-performance advanced polymer material for innovative lightweight transparent armor applications, and lightweight polymer cased small arms ammunition.
With many years of experience designing high-performance products for the military, FPPD has acquired advanced technical capabilities tailored to meet the most demanding challenges. Our highly experienced engineers are experts at utilizing cutting-edge modeling and simulation technology to analyze and validate designs, allowing us to streamline the R&D process and expedite product development. FPPD has a track record of devising testing procedures, designing prototype testing equipment, and helping its partners establish specifications for products. FPPD also specializes in the development and commercialization of innovative lightweight plastic materials, high-performance composites, and advanced nano-composites to meet the most demanding applications.
Four Pillars That Support Military Excellence
At FPP Defense, we strengthen U.S. Military capabilities through four essential pillars that drive every defense project. These foundational elements ensure we deliver mission-critical solutions that enhance military readiness, protect service members, and advance national defense objectives. Our commitment to these pillars has made us a trusted partner in military innovation and operational excellence.
Advanced Technology
We possess outstanding technical skills in materials, design, and prototype fabrication. Our advanced armor technology offers 40% weight savings, and our innovative lightweight small arms ammunitions offer more than 20% weight reduction.
Rapid Development
We understand the urgency of projects and we work diligently to deliver products in the shortest amount of time just as we accomplished with our MK12 plugs project with the Navy; working from scratch, delivering the prototypes, and passing the qualification tests within 12 months.
Success records
We have successfully developed and fielded critical components for the Navy's MK12 plugs, the Army's handheld signals package system, and are working to field advanced transparent armors and innovative lightweight small arms ammunitions.
CLose Collaboration
We prioritize close collaboration with all our military partners to develop a profound understanding of exactly what they need, and to ensure we exceed expectations along every step of the process.
DOD COLLABORATION PARTNERS
JPEO A&A
PM-MAS
JPEO A&A
PM-CAS
PEO Soldier
PM-Soldier Survivability
PEO Soldier
Project Manager Soldier Protective Equipment (PdM SPE)
NAVSEA NSWC
Picatinny Detachment
DEVCOM
Armaments Center
DEVCOM
Soldier Center
DEVCOM
Ground Vehicle Systems Center
DEVCOM
Army Research Laboratory (ARL)
MANTECH
Army Manufacturing Technology
NAVSEA
Ground Vehicle Systems Center
Marine corp
NAVAIR
Receive the first SBIR contract with the Army’s Natick Soldier Center (now DEVCOM-Solder Center)
to develop advanced lightweight transparent armor
Facility Expansion
at Picatinny to 5,000 ft2
2006
2008
Received a multiple-year contract from TARDEC (now is DEVCOM-Ground Vehicle Systems Center)
to develop lightweight composite armor materials
2010
Received a multi-year BAA contract from ARDEC
to develop lightweight composite container for mortar rounds
2014
Received the first production contract from the Navy
fielding the M27 poly plugs for US Navy’s 5” ammunitions
2015
Fielded the improved safety handheld signal packaging system for PM-CAS
and assisted the Army to transition the technology to production
2018
1st Expansion
to a new 25,000 sq ft facility in Parsippany, New Jersey
2020
Received funding supports from Army’s ManTech
to build a domestically manufacturing capability to produce the super-high strength plastic material (SHSPM) for transparent armor applications in New Jersey
Received a demonstration contract from Navy NAVSEA-NSWC
for lightweight small arms ammunition
2021
2nd Expansion
Increased footprint in Parsippany, New Jersey to 45,000 sq ft
2023
Received the funding from Army’s DEVCOM-Armaments Center and PM-MAS
for lightweight 7.62mm ammunition demonstration
2024
3rd Expansion
Added another 15,000 sq ft facility to a combined footprint of 60,000 sq ft
2025
New SHSPM laboratory and production lines
became operational
2005
Received the first SBIR contract With ARDEC
for development of the lightweight 5.56mm ammunition
2003
Started working with the Army’s ADREC (now DEVCOM-Armament Center)
for lightweight ammunition and wrote a report for JSSAP to identify the potential plastic materials for lightweight ammunition applications
Incorporated in New Jersey
Received First Two SBIR Contracts
one from DOE and another one from DOT
Set up R&D Facility inside Picatinny Arsenal
2001
MAJOR MILESTONES
Since our incorporation in 2001, FPP Defense has marked considerable milestones that showcase our growth and dedication to excellence in the polymer industry. We take pride in our achievements, which span technological advancements and strategic expansions. These milestones not only highlight our journey but also our unwavering commitment to providing top-tier performance polymers to our military stakeholders.
“Designing innovative solutions to lighten the load our soldiers bear is not just about creating something new - it's about solving real-world challenges through the perfect combination of scientific rigor, precise engineering, innovative design and strategic vision. At FPP Defense, we bridge the gap between cutting-edge research and practical applications to deliver solutions that meet our customer’s needs.”
Jerry Chung
President + FOUNDER
Jerry received a PhD in Materials Science and Engineering from the Massachusetts Institute of Technology, with a specialization in polymer materials. He subsequently joined the Engineered Plastic business unit of a global engineering plastic resin company as a Research Engineer and was eventually promoted to Principal Scientist. During his time there, he developed important plastic resin modification technologies and successfully commercialized numerous products for the automotive market. By the time Jerry left the company in early 2001 to start his own business, the annual sales of the products he developed for the company accounted for more than $15 million a year. Even after 25 years, several of the products he developed are still in the market today, despite his previous employer having sold its plastics business to another major resin company.
After founding FPP in 2001, Jerry has been able to develop and establish the novel technical capabilities of FPP steadily through the years of diligent work and partnership with the Army and Navy’s engineers and PMs. Under Jerry’s leadership, the company developed capabilities in component and system design, prototype fabrication and testing, as well as computer modeling and simulation, enabling FPP Defense to deliver comprehensive solutions to its customers. FPP Defense has been focusing on and prioritizing delivering a complete component and/or system solution that addresses our military partners’ needs. This is the foundation of FPP Defense.
Over the course of 25 years, Jerry has successfully grown the FPP Defense business and expanded the company's footprint from an initial space to 5,000 sq ft in 2006, 25,000 sq ft in 2018, 45,000 sq ft in 2021, and to 60,000 sq ft across two facilities today. Jerry is now focused on advancing the development and fielding of transparent armor and innovative lightweight small arms ammunition technologies in the coming years to meet the Army’s needs for reducing soldiers’ load.
state-of-the-art research facilities
Our research facilities enable direct collaboration with military stakeholders and rapid prototyping. Equipped for advanced manufacturing and testing, our facilities ensure the latest in polymer processing and defense-specific technology. Each facility is designed to meet rigorous military standards while maintaining the flexibility and adaptability to facilitate the most complex defense requirements.
Parsippany, NJ
-
40,000 sq ft R&D and production facility and can be expanded to 70,000 sq ft for future needs
- Equips with a state-of-the-art production line for manufacturing super-high strength polymer materials for advanced transparent and opaque armor applications
-
A lab-scale plastic resin compounding line for advance and novel plastic material developments or pilot manufacturing
-
Three high-capacity injection molding machines for prototype manufacturing and production runs
-
Two compression molding machines for composite maufacutring
-
A polyurethane casting line
-
Fully equipped QC lab with the capability with various material testing and analytical equipment
NEWTON, NJ
-
15,000 sq ft R&D and prototyping facility and can be expanded to 40,000 sq ft for future needs
-
Advance lightweight armor assembling and testing
-
Equips with a high-velocity air gun for FSP ballistic testing of transparent and opaque armor materials and prototypes
-
A unique cartridge loading, assembling and packing (LAP) capability for small caliber and medium caliber ammunitions
COMPREHENSIVE CAPABILITIES
Technical Excellence
With over two decades of experience in cutting-edge product designs and solutions, FPP Defense maintains comprehensive expertise in polymers and composites. Our extensive modeling capabilities and databases cover materials, processing, tooling, and machinery, enabling us to deliver innovative solutions across the entire product lifecycle.
Collaborative Innovation
Through strategic partnerships with industry leaders, academic institutions, and government agencies, FPP Defense develops practical and cost-effective system solutions. Our focus on performance, functionality, and productivity has led to successful commercialization of novel products across automotive, industrial, energy, and defense markets.
Future-Forward Vision
FPP Defense continues to lead the development of "next generation" lightweight solutions, addressing today's complex product development challenges with cost-effective, innovative approaches. Our commitment to advancement and excellence positions us at the forefront of materials technology and engineering solutions.
Market Focus
Our commitment to innovation extends across multiple industries, where we deliver specialized solutions tailored to each sector's unique challenges. Our expertise and capabilities serve the following key markets:
READY TO JOIN OUR TEAM?
At FPP Defense, we're always on the lookout for talented professionals to enhance our team. Our company fosters a collaborative and innovative work environment. If you're passionate about making a difference through exciting projects, we encourage you to reach out. Join us and help build the next line of defense!
