Prototyping for military applications:
How today’s concepts are shaping tomorrow’s reality
Technology is developing rapidly and innovative and efficient solutions are more in demand than ever, especially in the military sector.
Robots, drones, advanced military equipment and highly specialized vehicles are examples of systems that are constantly evolving.
However, before these technologies can go into series production and be tested in use, they must be tested in the form of prototypes. Prototype construction is therefore an essential step in turning today’s visions into tomorrow’s reality.
Below we look at some key processes used in prototyping for military applications.
Rapid prototyping
Rapid prototyping, often realized through additive manufacturing processes such as 3D printing, enables the rapid production of prototypes directly from CAD data. This technology significantly revolutionizes the development time of new systems. Whether it is complex drone parts, individual soldier equipment parts or customized robot elements – rapid prototyping allows developers to create physical models and test them for functionality in the shortest possible time. The rapid iteration process leads to more efficient and cost-effective development.
Technical model making
Technical model making is a tried and tested process that is primarily used in the design phase. Ureol sheets, foams and fillers are used to create scale models. These models offer designers and engineers the opportunity to evaluate the aesthetic and functional aspects of a new system. Especially for vehicles and housings for devices and systems, technical modeling provides valuable insights and allows for quick adjustments to the physical model.
A special surface treatment allows experience to be gained and initial field tests to be carried out.
GRP laminates
Glass fiber reinforced plastics (GRP) have become an integral part of prototype development. GRP laminates are often used to produce robust and lightweight components that can withstand high loads. In military applications, GRP prototypes can be used for structural components of vehicles, drones or protective armor.
Their resistance to mechanical influences and their thermal stability make them an ideal material for initial functional tests.
Integral foam molded parts
Integral flexible foam molded parts are often used for ergonomic and shock-absorbing parts. In military applications, for example, these molded parts could be used for seat upholstery in vehicles or for protective components in soldiers’ equipment. These molded parts offer an excellent combination of flexibility, comfort and protection, which is particularly important in operational situations.
Vacuum casting (elastic or hard molded parts)
Vacuum casting is a versatile process that can produce both elastic and hard molded parts. This technique is often used to produce prototypes from polyurethane resins that come very close to the quality of production parts. In military applications, housings, covers or tactical equipment can be produced in this way and tested for their suitability for practical use. Vacuum casting makes it possible to produce small batches of prototypes with high precision and relatively low costs.
CNC prototypes
CNC milling is a classic but still indispensable process in prototype construction. Computer-controlled milling machines can be used to machine metallic and non-metallic workpieces with high precision. This process is particularly ideal for military applications where high strength and accuracy are required. For example, complex structural components for robot arms or precise individual parts for military equipment can be milled and tested for functionality.
Conclusion
Prototype construction is of central importance for military applications, as it bridges the gap between innovative concepts and operational products. In each of these processes, the focus is on testing functionality and usability.
The more thoroughly and creatively this phase is approached, the more efficiently and effectively the final systems can meet the requirements of modern armed forces and thus transform today’s visions into tomorrow’s reality.