LIGHTWEIGHT AMMUNITION DESIGN

ENABLING DEVEOPMENT into MARKETABLE PRODUCTS

Vincent Battaglia, VP Operations, BML Tool & Mfg. Corp

Firearms/Ammunition SUMMIT
Rapid City, South Dakota
21 October ‘2010
 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

21 October 2010 COLT DEFENSE / BML TOOL 2

 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

20 May 2009 COLT DEFENSE / BML TOOL 3

 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.

20 May 2009 COLT DEFENSE / BML TOOL 4

 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.

20 May 2009 COLT DEFENSE / BML TOOL 5

 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.

20 May 2009 COLT DEFENSE / BML TOOL 6

 Specific problems with casings
• Brass has many positive
aspects:
– Heat transfer/extraction
– Elasticity
– Strength
• But there are negatives:
– Weight (firepower)
– Cost
– Corrosion

20 May 2009 COLT DEFENSE / BML TOOL 7

 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

20 May 2009 COLT DEFENSE / BML TOOL 8

 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.

20 May 2009 COLT DEFENSE / BML TOOL 9

 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”.

20 May 2009 COLT DEFENSE / BML TOOL 10

 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”

20 May 2009 COLT DEFENSE / BML TOOL 11

 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.

20 May 2009 COLT DEFENSE / BML TOOL 12

 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.

20 May 2009 COLT DEFENSE / BML TOOL 13

 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.

20 May 2009 COLT DEFENSE / BML TOOL 14

 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.

20 May 2009 COLT DEFENSE / BML TOOL 15

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

Largest OEM of Rifle length magazines.

Product Line quickly expanding into

several new areas.

20 May 2009 COLT DEFENSE / BML TOOL 16

20 May 2009 COLT DEFENSE / BML TOOL 17
PARALELL RESEARCH & BUSINESS DEVELOPMENT
1. VIABLE PROJECTS 1. IP Consideration – Achievable Patents
2. PROJECT DELIVERABLES 2. TIMELINE & COST Considerations
3. RESEARCH PROJECT PLAN 3. Specific Budget, Legal Consideration
4. INTERNAL RESOURCES -TASK 4. Internal Quotation – Develop Budget
5. EXTERNAL RESOURCES-TASK 5. External Considerations in Program
1. Consortiums, Trade Groups 1. Cost of Interaction
2. CRADA’s, Private Contract 2. Review Quotations to Budget
6. APPROVE PROGRAM

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

20 May 2009 COLT DEFENSE / BML TOOL 18

 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.

20 May 2009 COLT DEFENSE / BML TOOL 19

20 May 2009 COLT DEFENSE / BML TOOL 20