LIGHTWEIGHT AMMUNITION DESIGN

ENABLING DEVEOPMENT into MARKETABLE PRODUCTS

Vincent Battaglia, VP Operations, BML Tool & Mfg. CorpFirearms/Ammunition SUMMIT

Rapid City, South Dakota

21 October ‘2010

21 October 2010 COLT DEFENSE / BML TOOL 2

Introduction

• Colt / BML teaming relationship– Colt Defense is a leading designer, developer and manufacturer of

small arms and weapons systems for the U.S. Military, its allies and federal, state and local law enforcement agencies. 

– B.M.L. Tool & Mfg. Corp. has been serving the Metal Stamping industry for over thirty years with critical application tooling and parts and offers full engineering services for all needs including tool & die design as well as product design.

• NSAC Grant Award “Modular Case”- FY06 to FY07• Continuous Private Development• CTTSO- Phase 3 Grant Award “Polymer Spiral Case”- FY10

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Ammunition Program Objectives

• Develop Parallel Case Manufacturing with Brass Ammunition• Fragment the Ammunition Manufacturing process into the small

business community.• Meet or Exceed all current Government Ballistic Performance• Competitive pricing with existing Brass Case products• Program developed to service Cannon Caliber munitions;

50BMG to 80mm

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DEMIL ammo status is unsatisfactory

• DEMIL will grow from 447K tons (FY05) to 490K tons (FY09)

• Covered Storage Facilities could be full by FY 10-12

• Current annual DEMIL costs are estimated at $125 million.

• CAAA alone has 126K Tons with a yearly $5M storage cost.

• Aging stockpiles are harder and more expensive to handle.

• DEMIL activities need to have a diminishing course of action.

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Change is needed in ammo manufacturing

• Develop sub component to fast assembly systems and process

• Target goal: – 80% sub component– 20% live ammunition

• Dramatic culture change required to modernize current ammunition manufacturing activities.

• New Standards and Specifications need to be developed.

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Design & development objectives

• Create manufacturing systems to allow JIT manufacturing.• Partial mitigation of yearly “LIVE AMMO” supply through sub-

component stock pile and “AS NEEDED” assembly.• Consider GREEN components in both casing and Projectile

materials.• Scale: develop manufacturing systems for small arms through

mid cannon caliber ammunition (5.56mm – 40mm).• Need to recognize fiscal realities, costs need to deflate while

capabilities inflate.

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Specific problems with casings

• Brass has many positive aspects:– Heat transfer/extraction– Elasticity– Strength

• But there are negatives:– Weight (firepower)– Cost– Corrosion

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Two design solutions to casing problems

• MODULAR CASE– Hybrid Steel/Polymer System

for 50BMG and larger munitions.

– Can replace any conventional steel or brass bottle neck case.

• SPIRAL CASE– All-polymer molded case in two

parts Case Body and Rim Base. – Primary use for 5.56 through

50BMG small arms ammunition

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Modular case

• Variant Polymer/Steel design for 50CAL through 40MM.

• Skeleton Case Metal stamping with insert molded charge vessel.

• Good weight savings in large cases.

• Very strong hoop strength.• Modular Manufacturing for JIT or

SCAMP.

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Separate the case from the powder!

• Skelton case portion– A determined progressive metal

stamping of two drawn target areas rotated to a common centerline.

• Charge vessel – Propellant storage to charge

weight, purged, covered. – Stored as sub-component.

• Assembly of Charge Vessel – dynamically inserted into the

“Skeleton Case” followed by Primer for a “Live Round”.

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2nd variant, insert molded

• Second mode of manufacturing with “CHARGE VESSEL” as integral insert molded operation.

• The insert molded “Charge Vessel” allows the variant case to be assembled in conventional manner.

“SKELETON CASE” WITH INSERT MOLDED “CHARGE VESSEL”

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Spiral polymer case

• Benefits– Spiral Ribbing enhances “hoop

strength” – eliminates “heat transfer” – reduces “extraction friction by

70%.• Manufacturing process allows

for conventional bullet insertion in the SCAMP line or can be insert molded with the case.

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Benefits at the prototype stage

• Charge weight measurement within 5% of conventional 50BMG.

• Case weight savings of 47% over Brass.

• .091 lbs per round weight savings in 50BMG.

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Other spiral case features

• RIM/BASE COMPONENT– This is a molded component

with an insert stamping internal in the shape of an “H”, the bottom houses the primer with the flash hole pierced out and the top portion acts as a blast tray for ignition.

• ASSEMBLY & BONDING– Ribbed Perimeter adds

approximately 50% more perimeter for bonding and joint strength.

– Helical Twist of ribbing mitigates pressure force line at ignition. Also aids in the extraction sequence from the weapon.

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Manufacturing benefits

• Can be manufactured as a conventional case by bonding the rim/base to the case for conventional processes.

• Projectile can be insert molded to the case for a back fill technique.• Modularity allows JIT and stock pile of components.• NOT “LIVE” Ammunition.

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ACCURATE-MAG a new B.M.L. Tool product line.

Largest OEM of Rifle length magazines.

Product Line quickly expanding into several new areas.

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COLT DEFENSE / BML TOOL

1. VIABLE PROJECTS

2. PROJECT DELIVERABLES

3. RESEARCH PROJECT PLAN

4. INTERNAL RESOURCES -TASK

5. EXTERNAL RESOURCES-TASK1. Consortiums, Trade Groups

2. CRADA’s, Private Contract

1. IP Consideration – Achievable Patents

2. TIMELINE & COST Considerations

3. Specific Budget, Legal Consideration

4. Internal Quotation – Develop Budget

5. External Considerations in Program1. Cost of Interaction

2. Review Quotations to Budget

6. APPROVE PROGRAM

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PARALELL RESEARCH & BUSINESS DEVELOPMENT

PROGRAM MANAGEMENT EXECUTES LOGISTICS TO DELIVERABLES

• Program is Constrained by the Budget and Plan• Modifications to Project Plan, quickly go through approval cycle• Completed Deliverables

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ENABLING DEVEOPMENT

• Consider only valid designs that have a clear market path.• The Business Plan and Project Plan must have parallel goals of

reasonable market entry for profit.• Establish commercial partnerships with critical path Mentors

vendors.• Form or Join Consortiums in your field, there is safety in

Numbers.• Smaller Companies should consider partnerships with larger

Prime contractors if the relationship fits.• Make your local Government work for you, know whom your go

to people are.

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