BALLISTIC SAFETY SYSTEMS TECHNOLOGY

INDIA PVT LTD

Out of Box Thinking …

Out Standing Solutions …

Highest Combat Effectiveness

Lowest Cost of Ownership ……
DESIGNED FOR HIGHEST COMBAT EFFECTIVENESS

Mobility – Highest Operational Agility

Comfort - a) Snug Fit to the body
b) Better Sweat Management
c) Better Endurance & Wearability
d) Lowest Weight for Stopping Bullet
Protection – a) Superior Protection Against Automatic Weapons
b) Better Resistance Against Burst Fire
c) Withstands Highest Number of Shots / Unit Area
Cost effectiveness – a) Lower Cost Per Shot
b) Better Plannability: Midlife Integrity Monitoring
c) Test in Time: Inservice Integrity Testing
d) Life Cycle Costs: Lower Cost of Ownership

Highest Combat Effectiveness . . . .

Lowest Cost of Ownership . . .
PATENTS, TECHNOLOGY and ADVANTAGES
1. Process of Manufacturing High Quality Composite Materials using an Iso-Static
High Pressure Reactor (HPR). PCT Appln. No. PCT/IB2015/054913 claiming
priority of Indian Patent Appln. No. 3184/CHE/2014
Advantages
a) Uniform (3D) Pressure (350 bar) and Temperature (160°C)
b) Uniform and quick heat transfer and removal
c) Ability to monitor core temperatures of individual panels
d) Multi channel data logging of pressure and temperature (12 channels)
e) Single stage process (all components are fused and cured at one go)
i. No mismatch of tolerances in components
ii. Embedment of sensors for traceability and NDT monitoring
f) Curing of complex shapes
i. Riffle helmets, Ra-domes, Missile nose and engine
2. System and method of detecting the changes in structural health of a
composite panel. PCT Appln. No. PCT/IB2017/050916 claiming priority of
Indian Patent Appln. No. 201641005836
Advantages
a) Sensitive to changes in material properties i.e.,
i. Detects material degradation, changes in interfaces & their performance
b) Monitor and benchmark materials and manufacturing/curing
c) Monitor in-service performance changes in composite ballistic panels
i. Detect defect panels, rest life estimation, combat preparedness
ii. Saves lives & money, improves plannability
NIJ (III+ and IV) / BIS STANDARD INSERTS WITH DIFFERENT COMBINATIONS
PANELS TESTED AT TBRL / GFSU / AND IN DIFFERENT RANGES OF GERMANY

Monolith(SiC, B4C, Al2O3) Hex Tiles (SiC, B4C) Hex Tiles (SiC & B4C) Hex Tiles (SiC & B4C)

Ceramic/HDPE based solutions

a) B4C ceramics with HDPE backing using our unique patented process which provides more stabilization
b) SiC ceramics with HDPE backing using our unique patented process which provides more stabilization
c) Al2O3 ceramics monolithic as well as tiles with HDPE unique patented process which provides more stabilization
 TESTED AT GFSU – MULTI HIT CAPABILITY
Panels are Tested at Different Ranges in India and Germany

BULLETS FIRED FROM AK 47, HSC VARANGOAN STOPPED 25 FROM

A DISTANCE OF 10 METERS WITH A VELOCITY GREATER THAN 700 METERS / SEC
 DESIGNED FOR HIGHEST SURVIVBILITY – NIJ IV / BIS LEVEL VI BALLISTIC PANELS
With Embedded Sensors to Check Integrity of the Panel
Test Report : All six bullets are trapped in the insert

sensors

Strike Face View Face to Body View

1 6
7

5 2

3 4
Embedment of Sensors to sensors
X ray View X ray View
Check Midlife Integrity of Panels
Embedded Sensors to Monitor the
in-service Integrity of the Panel
NIJ Level IV Panel with Sensors Tested at Range of Teijin at Germany

1 6
7

X-Ray View
5 2

4
3

Front View
Rear View
a ny
in Ger m All six bullets are trapped in the insert
te d
Tes

7
Field Testing of BIS Level VI
With 7.62X54R API at Telangana

8
 BIS Level VI Panels Tested by Various Parties in Sep 2022

Panel Tested at TBRL Panel Tested at TBRL Panels Tested at TBRL

Total 15 panels are tested and

Further 10 panels in testing line Panels Tested
by a Private Party
 NEW GENERATION SNUG FIT BULLET GUARDS

Features
Advantages

a) Assured Protection a) Available in five different sizes

b) Highest Survivability b) Makes side plates redundant
c) Comfort & Agility c) Suits to different body structures
d) At Lowest Cost/Shot d) High comfort
e) Improved combat effectiveness

Studied and Validated by CSASDA/DRDO and tested at GFSU

Advantage

• Bullet Guard covers > 95 % rib cage (pleura exposed in highly

minimized)
• Bullet Guard Covers the spleen > 95 % of liver, pancreases and 75 % of
the Kidneys)
• Ergonomically greater comfort as spacula is not restricted
10
• Incapacitative index is low
 BSST BULLET GUARDS – 3D VOLUME SCANNED BY CSASDA / DRDO

Virtual Model of plate (3D volume scanned)

& Human Skelton (Anybody Software)

Ergonomic studies carried out

at CSASDA /DRDO on
BSST Bullet Guards. Back View
Front View
Virtual Coverage of plate (3D volume scanned) Side View
& 3d CT volumetric image

Advantage

• Bullet Guard covers > 95 % rib cage (pleura exposed in highly minimized)
• Bullet Guard Covers the spleen > 95 % of liver, pancreases and 75 % of the Kidneys)
• Ergonomically greater comfort as spacula is not restricted
• Incapacitative index is low 11
 SNUG FIT BULLET GUARDS X-RAY AND TEST REPORTS

Front Torso’s X-Ray

Rear Torso’s X-Ray

 PRESENT BIS STANDARD DESIGN PROPOSED CSASDA BSST BULLET GUARD DESIGN

CONCLUSIONS FROM CSASDA /DRDO STUDIES: Proposed Design : Advantages

• NIJ specified plate covers 75 to 80 % rib cage (Pleura exposed) • Cover the chest field completely, ergonomically and qualitatively
• NIJ specification equivalent plate does not cover the spleen and covers < 75 assess the area covered
% of liver and 25 % to 75 % of the kidneys depending the length of the plate • Cover the spleen completely and kidneys partially yet ergonomically
• Ergonomically NOT comfortable to wear as scapula is restricted and no body
Challenge:
contouring
• Area of coverage is primarily the heart and with respect to hex tile • Optimize the dimension of chest plate w.r.t variable chest
technology proposed the incapacitative index is high to moderate circumference 1
3
respectively • Design of back plate for highest ergonomics.
NEED OF THE HOUR – ASSURED PROTECTION – AGILITY – COMFORT – INTEGRITY MONITORING
Parameters Standard BIS Level V BSST Bullet Guard Standard BIS BSST Bullet Guard
Level - V (Front) Level VI Level – VI (Front)

Physical plate area 735 cm2 1120 cm2 700 cm2 1000 cm2

Assured protected area 298 cm2 959 cm2 250 cm2 675 cm2

% age of protected area 40% 86% < 40% > 75%

Number of shots allowed 6 12 3 6

Shot-to-shot distance 51mm 35mm 51mm 50mm

Shot-to-edge distance 51mm 35mm 51mm 40mm

Vital organs protection Partial Complete Partial Complete

Side Panels Required Not required Required Not required

Aerial Density 33 31 46 44

Soft Armor Panel (SAP) Required Not required Required Not required

Std solution weight for 3600 8.9 kg 7 kg

protection, including carrier and
trauma pad 14
 Rifle Helmet (NIJ Level III) Tested at GFSU with AK 47 MSC

TOP VIEW INSIDE VIEW X RAY VIEW

Five Trapped Bullets

1. Tested with Five (5)Shots with AK 47 MSC

2. Max Trauma 23 mm and Min Trauma is 0 mm

3. Max Speed 660 m/sec

4. Tested up to Max Speed 760 m/ sec with out perforation

Bullet Resistance Helmet (NIJ Level III +) Tested by NSG with AK 47 HSC

Tested at NSG Delhi

(see video clip)

Fired with AK 47 HSC with speed above 700 Meters/sec at Govt. Range.

Fired under field conditions from a distance of 20, 10 and 3 meters respectively.

16
Faulty Body Armour : "A Hidden Life Threat"
All our Body Armour can be with Embedded Sensors
• Ballistic Protection Jackets are used extensively by defence personnel, police and other security
services.
• Ballistic panels are prone to in-service damage due to ageing and in-service loading spectrum
involving
• Thermal Impacts: (Exposure to heat and Solar radiation)
• Radiation Impacts: (Ultraviolet radiation)
• Mechanical Impacts: (Due to damage, static and cyclic mechanical loading)
• The resulting defects like de-bonds, de-laminations, intralaminar and interlaminar matrix cracks and
fibre fracture can significantly curtail the useful life of the ballistic panels.
• These ballistic panels are to save the lives. But a damaged panel is nothing but dead weight.
• Developed cost effective (patented) non destructive method to detect in-service damages. Invisible
damages and performance degradation is detected. We are offering this service to segregate non
performing/degraded HAP panels and recondition the flawed panels at a nominal cost.
• This unique service saves environment, time and money.
• Our patented process enables the flawed HAPs to be reconditioned at nominal cost, this avoids
unnecessary causalities and increases combat effectiveness.
 ADVANTAGES OF OUR NEW NDT METHOD
Reconditioning of De-laminated and De-bonded Ceramic Composite Ballistic Panels

• A HAP panel in our laboratory was

subjected to temperature
exposure. The de-laminates and
de-bonds in it are recorded.

• We regenerated this panel using

our patented HPR process. We
could restore the panel condition
successfully.

BSST India Pvt Ltd

 ADVANTAGES OF OUR NEW NDT METHOD
QUALITY CHECKS OF RAW MATERIAL

Input on Ceramic Quality Input on Backing Material Quality

a) Sensitive to Compositional non uniformities a) Sensitive to Strength of fibre
b) Sensitive to Density non uniformities b) Sensitive to Fibre breakages
c) Detects Micro-Cracks in ceramics
BSST India Pvt Ltd
d) Sensitive to Porosity variations
 ADVANTAGES OF OUR NEW NDT METHOD
Damage Detection / Integrity Monitoring of Ballistic Panels
• The panel in figure was subjected to a
typical in-service blunt impact. The
impacted panel was transported under
usual conditions. Invisible damages and
performance degradation is recorded
using our method.

• It is observed that the degradation

continues in a damaged panel at much
higher speed endangering lives of
wearers.
BSST India Pvt Ltd
 Can Failure Prone Panels Predicted?

• Panels 02 & 03 are identical twins made

out of same lot of materials and process.
• Only Panel-02 is subjected to usage
relevant blunt impacts for trails.
• The Signatures were recorded in virgin
state and after blunt impact for Panel-02
and after ballistic testing for Panel 02 &
03.
• The low signature strength of Panel-02
confirms that its material integrity is
compromised.
• The same is observed in ballistic testing.
Panel 02 had two penetrations, whereas
Panel 03 stopped all bullets.
BSST India Pvt Ltd
 Panels with Low Signature Strengths failed in Ballistic Testing
X-Ray-02 NFSU Test Results
Subjected to Blunt Impacts Tested -02 As Predicted Panel failed
Identical twins: Panel-02 Low Signature Strengths. in ballistic testing. Two
Panel 02 & Panel 03 Predicted to fail in testing. penetrations in HAP.
are designed to
with stand AK-47
Not Subjected to Blunt Tested -03 As Predicted Panel passed
(HSC). These have Panel-03
Impacts. High Signature in ballistic testing. No
high initial NDT
Strengths. penetrations in HAP.
signature strengths.
Predicted to pass in testing. X-Ray-03

Panel-2846 Not Subjected to Blunt Tested X-Ray 2846

Impacts. High Signature 2846 As Predicted Panel passed
Strengths. in ballistic testing. No
Identical Panels:
Predicted to pass in testing. penetrations in HAP.
Panel 2846, Panel
2848 & Panel 2849
are designed to Panel-2848 Subjected to Blunt Impacts Tested X-Ray 2848
2848
As Predicted Panel failed
with stand AK-47 and temperature aging.
in ballistic testing. One
(HSC). These have Low Signature Strengths.
Predicted to fail in testing.
penetration in HAP.
high initial NDT
signature strengths.
Tested X-Ray 2849
Subjected to Blunt Impacts
Panel-2849 India PvtAs
2849
BSST LtdPredicted Panel failed
and temperature cycling. in ballistic testing. Three
Low Signature Strengths.
penetrations in HAP.
Predicted to fail in testing.
 NO-COST, NO COMMITMENT (NCNC) – TEST RESULTS
of Field Used Ballistic Panels
Under Imprint Project: #1756

Project Name : "Non-destructive damage detection and damage quantification in composite (HAP) panels:'”

On NCNC bases one of the Indian Army “XXXXX team” submitted randomly selected twelve (12) field used
Hard Armour Panels. They fell into two groups in appearance (visual inspection).
1. Panels with Blue outer cover and

2. Panels with Black outer cover.

Blue panels appear to have been in service for longer time and have undergone more rugged usage. Whereas
the black covered panels have been used less and appear to be in good condition. Further it is noted that the
blue covered panels seems to be from two different procurement lots falling into two different batches. We
assume that unit has procured these panels at three different time intervals. The panels received are analysed
BSST India Pvt Ltd
with our methodology and the results documented.
 OUR OBSERVATIONS AND RECOMMENDATIONS

S. No Panel ID Colour Signal Volume Group

1 XXXXX Blue Panels 66.71 1
2 XXXXX Blue Panels 43.44 2 • We observe that one out of 12 panels
3 XXXXX Blue Panels 49.04 2
4 XXXXX Blue Panels 63.69 1
5 XXXXX Blue Panels 28.73 3 with ID “XXXXX” (no. 12), with very
6 XXXXX Blue Panels 18.01 3
7 XXXXX Blue Panels 1.33 4 low signature volume, which we advise
8 XXXXX Blue Panels 40.17 2 Ltd
BSST India Pvt
9 XXXXX Black Panels 47.56 2
10 XXXXX Black Panels 48.19 2
NOT TO BE USED.
11 XXXXX Black Panels 49.76 2
12 XXXXX Black Panels 22.75 3
CLUSTER DIAGRAM – Of Army Unit Field Used Ballistic Panels
Cluster Diagrams:

Adjacent cluster diagram is created

from collected signatures. Signal
strength and Signal position are plotted
as a function of signal volume. One can
see that all these 12 panels fall into four
distinct groups. The panels with
smallest signal volumes are considered
to be the weakest. The panels with
strongest signal volumes are considered
to be in good condition.
BSST India Pvt Ltd
SMART SOLDIER FULL BODY PROTECTION (NIJ IV) SYSTEM
WITH IN-BUILT IN INTEGRITY MONITORING

RhinoDerm RhinoDerm RhinoDerm

Use Always Use at Work Emergency Use
Basic- Pistol Level III or Level III or
Level III+ or Level III+ or
BSST India Pvt Ltd
Human Level IV Level IV RhinoDerm
Health Embedded System Integrity Use on Mission
26
Monitoring Sensors Monitoring
 1. New Virgin Technology Developed in India
(CNT & Graphene in 2017)

2. In build Health Monitoring Sensors (2016)

3. Tested with 2 bullets

With CNT

Without CNT

X Rays of the impacted panels with sensors after the bullets are fired,
i.e panel without CNT and with CNT incorporation.
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Graphene Stabilised bolt-able ballistic panels for vehicles / Objects.
Cost Effective Multi-hit Panels

Cost effective - NIJ Level IV

Cost Effective - Multi-Hit Capable Boltable Ceramic Matrixes.
Graphene Stabilized - Bolt-able Inserts
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 Dr. P. Mahavadi,
Email : pmahavadi@mahavadi.com
Cell : +91-95732 56781, + 49 172 9572 737