Ballistic Composite Laminate Design With CAE-Led Rapid Validation
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Solution Overview
Problem
The traditional development of new ballistic materials into new articles is a time- and labor-consuming process, requiring extensive destructive testing with live ammunition, which is inefficient and not suitable for urgent needs of security or safety responders, given the multi-year procurement cycles.
Innovation Solution
The method employs Computer Aided Engineering (CAE) for initial performance challenges in designing ballistic solutions, using existing solutions as a starting point, with alpha stage prototypes tested physically, and iterating based on simulation results, utilizing CAD programs for material property adjustments and advanced simulations to reduce unnecessary testing and optimize material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional iterative design and development process is used, then ballistic resistant performance is ensured through extensive destructive testing, but development time and labor consumption increase significantly
Solution Approach 1:
The patent applies preliminary action by performing CAE simulations and virtual ballistic testing before physical prototype fabrication. This allows design validation and optimization to occur in the digital domain first, reducing the need for multiple iterative physical tests and accelerating the development timeline while maintaining reliability standards.
Solution Approach 2:
The patent uses digital twins and virtual models as copies of physical ballistic articles to perform testing and validation. These digital replicas allow extensive testing scenarios to be evaluated without consuming physical materials or requiring actual ballistic testing until final validation, significantly reducing development time while ensuring performance requirements are met.
2Reliability
If extensive destructive testing with live ammunition is performed, then ballistic performance validation is achieved, but cost and time resources are consumed
Solution Approach 1:
The patent replaces physical ballistic testing with virtual ballistic testing using CAE simulations. These simulations create digital copies of the testing process, allowing multiple test scenarios to be evaluated without consuming ammunition, target materials, or requiring physical test facilities until final validation is required.
Solution Approach 2:
The patent substitutes mechanical ballistic testing systems with computational mechanics-based CAE simulation systems. This replacement allows ballistic performance to be validated through mathematical models and virtual experiments, dramatically reducing consumption of physical resources while maintaining validation reliability.
3Manufacturing precision
If multiple iterations of design and testing are conducted, then optimal product performance is achieved, but development complexity and resource requirements increase
Solution Approach 1:
The patent replaces complex physical iteration processes with computational simulations. CAE tools allow rapid evaluation of multiple design variants through virtual testing, reducing the complexity of managing physical prototypes and test setups while enabling more thorough performance optimization through efficient digital experimentation.
Data Source
AI summary
A method for the design and development of new ballistic resistant articles is provided. Improved ballistic articles are formed of polyethylene-based composite laminated structures having unique material properties including material density, Poisson's ratio, and modulus of elasticity (Young's modulus). Cycle time for completing design and development is less than 30 calendar days.