Project Low profile body armour Huijun Li University of Wollongong

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Ella Wilcox
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1 Project Low profile body armour Huijun Li University of Wollongong April 7, 2009 Capability through collaboration

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3 Company overview 3

4 Company overview 4

5 Business model and governance 5

6 Personnel survivability DMTC - Program 7 6

7 DMTCF Program 7 7

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9 Program Goals 9

10 Project overviews 10

11 DMTC Low Profile Body Armour DMTC LTD. Hawthorn, Victoria, Australia University of Wollongong, New South Wales, Australia Australian Defence Apparel Pty Ltd. Coburg, Victoria, Australia BlueScope Steel Ltd. New South Wales, Australia 11

12 DMTC Project Outcome Martensitic steels are commonly used for armour applications owing to their high hardness and good ballistic resistance. This project will carry out an evaluation of a series of high hardness steels for low profile body armour application and provide prototype designs for consideration by Australian Defence Force personnel. 12

13 DMTC The first stage will be a comprehensive assessment of current products, package design and generic threats. This will be achieved by analysing perceived generic threats, determine the required material properties and identify weaknesses in current knowledge, and searching international databases for information on ferritic armour materials and applications. A wide range of high hardness steels will be assessed, and/or procured, including superbainitic steel, ARMOX grade, MARS grade, Bis-plates, high carbon alloy steels (eg. razor blade steels)as well as martensitic stainless steels. It is anticipated that a research fellow will be allocated to conduct research and package development in conjunction with the partners. 13

14 Ceramic and steel armour 14

15 Low profile armour Low profile body armour systems are intended to complement existing body armour designs with the benefit of being less bulky and allow greater movability while being worn. Research demonstrated the potential for ultra high hardness steels (UHHS) to fill the role of trauma plate defence in the low profile body armour system. optimisation is continuing. 15

16 Low profile armour Two prototype designs of the low profile body armour system have been manufactured based on the type of UHHS being used. Conventional armour grade high carbon steels have been formed using a hot quench press technique to produce three dimensional curved plates. High carbon stainless steel plates have been formed using a bend forming technique to produce plates with curvature in one dimension. The high carbon stainless steel plates were subsequently processed by ADA defence technologies to produce a completed prototype design. UHHS ballistic property optimisation is continuing. 16

17 Low profile armour Standard low profile body armour plate, Pacific 8ft Hydraulic Panbrake bend forming system and formed plate cross-sections 17

18 HIA 18

19 HTA 19

20 Armox440T Armox500T 20

21 Mars220 SS SS 21

22 Future work Ballistic testing Microstructural analysis Fracture analysis, Bend testing (at different temperatures) Surface profiling, Investigation on armour lining materials 22

23 Future work proposal Although protection must always be the priority, comfort can no longer be considered as simply a luxury. Therefore, focus in armour design must increase emphasis on reducing the physical strain on a soldier that can lead to long-term injury. Armour must fit properly in order to work efficiently. Ill-fitting body armour that results in excessive armour weight burden and mobility restrictions has very real short term consequences for survivability, and long term implications for a soldier s productivity and quality of life. 23

24 Future work proposal The proposed project will focus on developing an Advanced Armour Lining for this armour system, and integrating the Low Profile Steel Plate with the improved lining. The Advanced Armour Lining will focus on improving user comfort by improving breathability and wearability. It will offer excellent impact absorption and prevent fragment penetration, in order to enhance ballistic protection. The Advanced Lining System will be manufactured using 3D printing technology, and based on scanning each individual s body to provide a custom-fitted armour system for each individual soldier. 24

25 Future work proposal Design and develop a fitted smarttextiles compression layer to enhance comfort, breathability and overall muscle recovery. For female personnel, this layer will also include built breast support. Use a 3D body scanner to inform 3D printer designs: Namely, design and develop computational program capabilities to convert a 3D body scan into a 3D printed Advanced Armour Lining. Design and develop a 3D printed Advanced Armour Lining and integrate with a Low Profile Steel Plate, to create a light-weight, functionally flexible, Advanced Personnel Armour System, which offers the ultimate in next-generation ballistic protection. End Product: A layered system comprising of smart-textiles for comfort and support, and a light-weight, functionally flexible, 3D printed Advanced Armour Lining with a Low Profile Steel Plate, custom designed to each soldier s individual body scan specifications. 25

26 Future work proposal BIOMECHANICAL ASSESSMENT OF THE ADVANCED PERSONNEL ARMOUR SYSTEM Once developed, the bio-impact of the Advanced Personnel Armour System will be tested using an integrative biomechanical analysis to ascertain: (i) maneuverability in the Advanced Personnel Armour System while performing functional tasks; and (ii) (ii) the physiological and biomechanical responses of a soldier while wearing the Advanced Personnel Armour System to ballistic impact (with different projectiles and speeds). This will be done by integrating high speed camera footage; 3D motion analysis; physiological responses (heart rate, blood pressure and thermoregulation); pressure measurements between the soldier and armour system interface; and mathematical modelling. 26

27 Future work proposal Female-specific Body Armour: The role of women in the military is substantially increasing. In both Australia and the USA the ban for women serving in frontline combat roles was lifted on1 st January 2013; opening for the first time in history, options for women in the artillery, armoured, infantry and engineering units of the Army. By utilising the proposed body scan techniques for an Advanced Armour Lining, this project will ensure women moving into combat roles have the ultimate in body protection, without compromising fit due to their significantly different anthropometric structure relative to their male counterparts. 27

28 Future work proposal Wearable electronics: Recent work at the ARC Centre for Excellence for Electromaterials Science (UOW) has developed a strong and flexible yarn that can be used to power wearable electronics. There may be a capacity to integrate this innovative technology into the Advanced Armour Lining to provide physiological (e.g. heart rate) and motion data (e.g. speed) regarding the wearer. 28

29 Other Discussion/Questions 29

Assessing the Methodology for Testing Body Armor

Assessing the Methodology for Testing Body Armor Ronald D. Fricker, Jr. Naval Postgraduate School and Alyson G. Wilson Iowa State University August 1, 2010 Background Armor manufactured from various materials