lightweight solutions
Novel Lightweight Solutions
Delivering Advanced Technical Products For The U.S. Army And Navy
HIGHT TEMPERATURE RESISTANT COMPOSITE ARMOR
FPP Defense has successfully executed an SBIR contract to develop a high-temperature-resistant (500F) composite armor for Marine Corps EFV applications.
An innovative melt processable polyamideimide composite armor material technology was developed using a novel solution pre-preg impregnation process to produce cost-effective high temperature composite armor with the following benefits
Temperature resistant up to 545°F
Significantly lower resin and manufacturing costs than thermoset resins such as PMR-15
Exceptional heat aging resistance and almost no strength loss at 480°F for more than 5000 hours
Good petroleum fuel and saltwater resistance for EFV applications
Maintain more than 90% ballistic resistance at 500°F
The thermoplastic polyamideimide resin has melt processability and becomes a high-strength thermoset resin after going through post-curing. The tensile strength of the PAI S-glass composite is 80.6 Ksi, which is higher than the 70.3 Ksi of conventional HJ1 armor material, even before post-curing. After post-curing, the PAI becomes a thermoset resin, and the tensile strength at ambient of PAI-unidirectional S-glass composite increases to 116 Ksi, which is more than 50% higher than that of conventional HJ1. The V50 per areal density of PAI unidirectional composite is 15% higher than that of HJ-1 composite at ambient, while it still maintains 90% of ballistic performance at a temperature as high as 500°F to meet EFV’s application.
LIGHTWEIGHT ADVANCED GLASS ARMOR
PEO Combat Support & Combat Service Support sought a lightweight, cost-effective alternative to the heavy glass armor currently used in M-ATV side windows—approximately 100 square inches for the rear and 300 square inches for the front. The initiative supports the Army’s broader goals of reducing logistical burdens by lowering vehicle weight, improving soldier situational awareness, and decreasing door weight to facilitate easier egress during rollover accidents or similar events.
The new transparent armor technology must directly replace the current ceramic-based windows on the M-ATV, with a target of reducing weight by 50% compared to traditional ballistic glass. Additionally, the cost must not exceed three times that of standard glass.
Although advanced materials like ALON and Spinel have demonstrated the ability to achieve the desired weight savings, their current cost—roughly ten times that of glass—renders them impractical for vehicle use. Because the M-ATV's side windows are currently limited in size due to weight constraints, reducing the weight of the transparent armor is a critical first step toward enabling larger windows, which would enhance rear occupant visibility and situational awareness.
Working under an SBIR contract, FPPD has developed a constrained armor technology using a specialized, cost-effective glass material tailored for this application. The technology successfully demonstrated a 50% weight reduction compared to traditional glass armor—meeting performance goals without the high cost typically associated with advanced transparent armor. FPPD’s advanced glass armor is priced 30% below the government’s target cost of three times that of current glass, with the potential for even greater savings at larger production volumes. Additionally, FPPD developed a novel surface coating technique that enhances the multi-hit performance of this lightweight glass armor.
LIGHTWEIGHT COMPOSITE CONTAINERS FOR MORTAR AMMUNITION
Traditional mortar round ammunition is packed in heavy rectangular steel containers with fiberboard, aluminum foil, or asphalt fiber tubes. An example of this packaging system is the 120mm mortar ammunition, originally developed in the 1990s. This packaging consists of two PA153 fiber containers placed inside a PA154 metal container, with a total weight of 101 lbs. This exceeds the 90-pound limit per soldier, requiring two for transport, which limits mobility and combat agility.
Over the past decade, the U.S. Army has worked to refine ammunition packaging systems. Picatinny Arsenal even developed the Monopack, an all-composite container designed for 120mm mortar rounds. While Monopack offered strong structural integrity and toughness, it still failed to protect the mortar round’s fins.
FPPD has successfully developed an innovative composite container packaging system, featuring a novel hybrid cushion design that enhances energy absorption and protects mortar round fins during impact. The composite container consists of a cap and body with a cylindrical shape, specifically designed to house a mortar round. A unique fastening system and sealing gasket ensure a seamless connection between the cap and body. These lightweight, cost-effective containers provide superior shock and vibration protection, enhancing battlefield mobility. FPPD’s packaging system enables soldiers to carry ammunition more easily and with greater protection, thereby improving operational effectiveness. Tailored to specific ammunition types, these composite containers offer a reliable, advanced solution to modern military logistics, ensuring optimal performance in critical combat situations.