Lightweight Ballistic Armor for Military Aircraft Navy SBIR FY2005.1 Sol No.: Navy SBIR FY2005.1 Topic No.: N05-023 Topic Title: Lightweight Ballistic Armor for Military Aircraft Proposal No.: N051-023-0244 Firm: Systems and Materials Reserach Consultancy 19300 Crosswind Circle Spicewood, Texas 78669-5100 Contact: Alan Bray Phone: (512) 263-0822 Web Site: systemsandmaterials.com Abstract: CBDO copolymers and nanocomposites are revolutionary transparent armor materials with higher notched Izod impact strength than any other polymer. CBDO copolymer and nanocomposite based aircraft armored transparencies will be lightweight, have superior anti-ballistic performance, and sell at commodity prices. Phase I armor laminates are to be made with CBDO based plies substituted for glass and polycarbonate/acrylic plies in currently fielded armor. Hard CBDO nanocomposites will replace face plies, and high impact CBDO copolymers will replace spall and intermediate plies. Phase I laminates will be used to demonstrate ballistic resistance to increasingly powerful weapon challenges in live fire tests building up to a 7.62 x 39 mm in the base period, and 7.62 x 51 mm in the option period. The net change in areal density for aircraft windows/windshields is expected to be 4 - 6 lbs./ft.2 for protection levels 1 and 2. Pilot production via OEM is identified and bids received for Phase II scale up. CBDO copolymer/nanocomposite armor resins in pelletized format - ready for sheet molding and armor laminate formation - are SMRC's product goal. Two transparent armor manufacturers and an aircraft transparency maker have signed on to help develop this new armor ply technology, providing test and aircraft integration expertise. Benefits: The best transparent armor clear laminate ply on the market today is polycarbonate based (Lexan/Zelux). Armor laminates using Lexan are in service throughout the military, but their effectiveness is ultimately limited by their impact strength and hardness. The market for clear armor laminates is performance, weight and cost driven. At a projected cost of $1/lb. and with significant weight reduction from higher performance, there is an obvious market for CBDO based ply materials in the armor industry. We have teamed with two manufacturers with product lines in transparent armor and an aircraft transparency manufacturer - all interested in licensing the product after development. The SMRC CBDO based armor business plan calls for commodity levels of production by 2009. Return