Capabilities and Operations
The shooting range is a 30-meter-long tunnel that enables testing across a broad range of calibers. It accommodates small and medium calibers, including .22 LR, 9mm, 14.5mm Armour Piercing, and 20mm diameter artillery shell fragment simulants. Testing is conducted five days a week , with a capacity to shoot 5,000 projectiles a year.
The US ballistics range is capable of testing both direct fire threats and fragment simulating projectiles. Direct fire threats range from 0.17-cal to 14.5mm Armor Piercing threats, and fragments from a 2gr RCC all the way to a 20mm. The range is set up in accordance with NIJ and MIL-STD requirements for velocity detection, drag calculation, and operation methodology.
The tested targets include raw materials, finished products, and samples such as body armour inserts, vests, vehicle armour coupons, and 3D-shaped components like helicopter doors.
To meet the diverse requirements of different applications, the facility can simulate specific conditions. Samples can be conditioned in controlled hot or cold environments with managed humidity before testing. Powder loads are individually adjusted to match specified velocities or to simulate stand-off scenarios. For example, helicopter armour, typically tested for threats at a 100–300m range, is tested at 30m with calculated impact velocities representing those distances.
David Bianchini, Head of Materials Research and Development, emphasizes the importance of rigorous testing: “Our comprehensive ballistic testing protocols are essential to ensure that our advanced composite materials meet the highest standards of performance and safety.”
Advanced Testing and Documentation
The testing facility integrates advanced equipment and methodologies, matching standards used by leading European certified proof houses. Testing includes velocity measurements for every shot, high-speed cameras for impact analysis, and trauma assessment using plasteline clay of various types.
Data from internal tests and those conducted at certified proof houses are stored in Integris’ Ballistic Test Results (BTR) database. This database contains over 5,000 ballistic configurations, documented threats and material build-ups. This data enables comprehensive analysis and continuous improvement in armour development.
Erik Johnson, Senior Vice President of Engineering based at Integris in the USA states, “The US range is committed to ensuring exceptional quality and precision in testing, driven by the expertise of former law enforcement and corrections professionals who understand the critical demands placed on those using our products.”
Collaboration and Witness Testing
Integris welcomes customers, including renowned OEMs and end users such as Ministries of Defence, to observe tests of their armour systems. This collaborative approach ensures transparency and builds confidence in product performance.
Regular technical exchanges with certified proof houses further enhance the range’s capabilities. These exchanges validate the consistency of ammunition batches, especially amid challenges in sourcing ammunition like Russian-made stock. Comparisons are made using steel coupons to align with standard expectations and proof house benchmarks.
Safety Measures
Safety is integral to the shooting range’s operations. The gun barrel is mounted on a fixed chassis, and ammunition is electrically initiated from a control room shielded by armoured glass and walls. High-flow ventilation systems remove fumes and dust from the tunnel, and the ammunition storage area is equipped with multiple safety measures audited and approved by authorities.
Supporting Armour Development
The shooting range serves as a critical step in armour development. While the final products undergo approval at official proof houses, the facility accelerates the development process and enhances quality control. The integration of advanced testing techniques and rigorous safety measures positions Integris as a leader in ballistic protection solutions.
Bianchini further notes, “By continually refining our testing methodologies, we stay at the forefront of innovation, delivering solutions that effectively address the evolving challenges in defense and aerospace applications.”
Learn more about our ballistic capabilities.
