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5 Dec 2024
3D printing in ballistic protection
Additive manufacturing, also referred to as 3D printing, is revolutionising the field of ballistic protection. With its unparalleled design flexibility and material optimisation, 3D printing is bringing ground-breaking advances. Processes such as Selective Laser Melting (SLM) enable the production of armour steel, offering significant benefits such as reduced weight, increased design complexity and enhanced multi-functionality for platform protection systems.
In this blog post, we highlight the key aspects of this pioneering manufacturing technology and its application in the field of platform protection solutions.
The role of 3D printing in ballistic protection
Additive manufacturing originated in the 1980s and is closely linked to the development of stereolithography (SLA), invented by Charles Hull in 1983. This technology was the first to enable the creation of objects by curing liquid resin layer by layer using a UV laser. What began as an experimental technology for prototyping has become a key method for producing complex and high performance structures. Its potential is particularly evident in ballistic protection, where both material properties and design play a critical role.
One of the most important 3D printing methods for ballistic applications is Selective Laser Melting (SLM). This process enables the processing of high-performance materials such as titanium, aluminium or special steel alloys, which are characterised by their strength and lightness. In ballistic protection, where material hardness and energy absorption are important, this technology offers an ideal basis for producing lightweight yet extremely robust protective components. Layer-by-layer production allows structures to be created that would be impossible using conventional production methods.
Freedom of design and innovation
A key advantage of 3D printing is the almost unlimited freedom of design. Conventional manufacturing methods such as milling or moulding often reach their limits, particularly with complex geometries. In contrast, 3D printing enables the realisation of innovative designs that would be impossible with conventional techniques.
In the field of ballistic protection, this opens up the possibility of developing structures that combine protection with functionality. For example, honeycomb designs or material placement by load paths can be realized that ensure optimum energy distribution in the event of an impact. Such structures not only offer greater protection, but can also reduce weight – a decisive factor for the mobility of vehicles, aircraft and personal protective equipment.
3D printing also allows multiple functions to be integrated into a single component. For instance, cooling channels or channels for pressure air can be embedded directly into the protective structures, adding value such as thermal signature reduction.
Practical validation of advanced protection solutions
The theory is promising, but the true success of 3D printing in ballistic protection will ultimately be determined through practical application.
An application example is the development of window frames with VPAM-9 protection that can withstand the highest ballistic requirements while significantly reducing vehicle weight. This lightweight construction brings advantages such as improved agility and increased fuel efficiency. Continuous research and development ensures that the technology is ready for future threats. Thanks to the flexibility and adaptability of this solution, 3D printing has the potential to revolutionise many fields of application.
Sustainability and cost efficiency
Beyond functional benefits, 3D printing offers significant advantages in sustainability and cost efficiency. A major benefit is the substantial reduction in lead times. Additive manufacturing enables faster production of components, eliminating the need for extensive post-processing. This process uses only the material that is actually required, reducing material costs and waste, which is both more cost-effective and environmentally friendly. In time-sensitive applications where quick action is essential, 3D printing provides invaluable flexibility and efficiency, meeting the demands of modern safety solutions.
Summary
In summary, additive manufacturing is a key technology driving the evolution of modern protection systems. It uniquely combines design freedom, efficiency, and sustainability, with the potential to reshape the future of security solutions. Ongoing research and development will be vital to meet the growing demands for advanced ballistic protection.
Learn more about the innovative possibilities of 3D printing and explore how this technology is setting new standards in ballistic protection solutions.
Sources
- 3Dnatives (21.11.2024), What Is Additive Manufacturing?
- 3Dnatives (21.11.2024), The Complete Guide to Stereolithography (SLA) in 3D Printing
Images and graphics: Mehler Protection, Mehler Engineered Defence GmbH (All rights reserved, 2024)
Our technology
In our PROTEC3D video, we showcase the innovative product family and the advanced technology behind it. This allows us to create complex geometries and integrate multiple functions, offering unrivalled design flexibility and structural integrity. Through the use of Selective Laser Melting (SLM), we can produce customised, durable steel armour components. These components deliver exceptional ballistic performance and provide consistent, reliable protection in the harshest environments.
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