Ballistic protection through 3D printing technology

Mahler protection PROTEC3D combines 3D printing technology with ballistic protection solutions. The new range features greater design flexibility, lower weight and more complex components.

The use of additive manufacturing, also known as 3D printing, is revolutionizing the production of ballistic protection solutions. The Selective Laser Melting (SLM) process can be used to produce custom components that ensure consistent ballistic resistance. This enables the production of components that would be difficult to achieve using traditional manufacturing methods. In addition, cathodic dip coating (CDC) improves corrosion protection of printed parts without compromising ballistic properties, which is often an issue with conventional armor steel.

The main advantage of 3D printing technology is the ability to produce complex components in a single manufacturing step. This results in lower overall weight and increased structural integrity of the protection solutions. In addition, additional functions such as integrated cooling channels and mounting points can be integrated directly into the component, increasing the reliability and service life of the products.

Mehler Protection uses this technology to optimize the production process while reducing costs and lead times. While traditional methods often require complex tooling and long manufacturing times, prototypes and small series can be produced within a few days using 3D printing. This is particularly useful for time-critical applications and allows flexible adaptation to specific customer requirements.

The new PROTEC3D series meets the requirements of the STANAG 4569 standard and is already in use in civil defense vehicles, featuring a significant reduction in the weight of protective window frames. At Eurosatory 2024 in Paris, Mehler Protection presented the PROTEC3D sensor housing that not only meets protection class 3, but also has integrated cleaning and cooling functions. These innovations demonstrate the potential of 3D printing to further improve the performance and adaptability of ballistic protection solutions.

Through the continued development of PROTEC3D, Mehler Protection positions itself as a provider of advanced protection technologies that meet the growing requirements for flexibility and efficiency in security-related fields.