Lightweight Hybrid Foamed Composite for Small Arms Protective Inserts

The current ballistic material systems for small arms protective inserts in personnel armor are based on ceramic plates with fiber-reinforced composite backing. The current Interceptor OTV (Outer Tactical Vest) and SAPI (Small Arms Protective Inserts) have saved many lives, but the current configuration is still not light enough to meet the goals of the Marine Corps System Command. Ballistic resistant materials that can be used for personnel armor protective inserts include metals, ceramics, polymeric composites, and their combinations. Current designs incorporating ceramic plates with a fiber-reinforced composite backing material can defeat some rifle shots and fragmentation, but these ceramic plates, even in their current configuration, are too heavy and suffer from inadequate multi-hit protection. In this Phase I research, we propose to develop a lightweight ballistic composite to replace the current material systems. The ballistic composite will be fabricated by a single-step technique without the use of any hazardous chemicals. It is engineered to defeat rifle shots at close positions. Preliminary experiments have shown very promising results. They are lightweight and are excellent for applications that require mobility. Additional features include the ability to resist fragmentation from neighboring damaged components. If successfully developed, the proposed materials would have an immediate and large market in the military, and civilian law enforcement community.