Transformative Carrier-Less Body Armor Using Additive Manufacturing and Dicyclopentadiene Resin

Carrier-based body armor systems, while effective, present several limitations that impact Airmen performance, safety, and operational flexibility. These challenges include excessive weight, inadequate protection against diverse threats, limited modularity, high costs, discomfort for various body types, and the reliance on materials that may fragment upon impact. A.M. Toolbox seeks to solve this problem with our carrier-less body armor utilizing Dicyclopentadiene (DCPD) resin-based composite materials. We have developed our concept to the point where it offers an NIJ-certified rating at Level 4 or Level III+. This new approach aims to significantly improve Airmen protection by offering a lightweight, highly protective, and anatomically adaptable body armor system. The armor’s modular nature allows for customization to fit the specific needs of various missions and environments, ensuring Airmen are equipped with precisely tailored protection. It is water and sweat resistant and more ergonomic than current body armor carriers. The ability to accommodate anatomical variations significantly increases comfort and usability for all soldiers, including women, ultimately improving troop morale and operational effectiveness. Our armor solution can be adapted and customized to specific Department of the Air Force mission sets with personal heating/cooling elements, recording devices, location monitors, biometric monitoring and other necessary items, such as first aid kits, tools, etc. A.M. Toolbox holds a patent on the tooling used for printing this body armor using additive manufacturing techniques and domestically sourced materials, reducing the reliance on foreign materials and supply chain issues.