UGVs Being Developed for Dangerous Missions

Unmanned platforms, from unmanned aerial vehicles [drones] to robotic vehicles on the ground [UGV], represent a capability extension in many areas, including use of weapons.

The Rise of the Robots

UGVs were mainly used to eliminate explosive objects. Thousands of UGVs were, for example, used in Iraq and Afghanistan in 2011. Many hundreds of others are used in law enforcement and rescue operations. The UGVs were used to eliminate improvised explosive devices (IEDs).

QinetiQ, with North America’s TALON family of robots, was introduced in 1995 and has earned a reputation for durability, flexibility, modularity and performance in keeping personnel, assets and civilians out of harm’s way. In the military, The TALONs are widely deployed by law enforcement and military for IED, explosive ordnance disposal (EOD) and HAZMAT (hazardous materials). TALON robots have been in continuous, active military service since 1995. They were successfully used in Bosnia for the safe movement and disposal of live grenades. Out of the two robot types used at Ground Zero, TALON robots were the only ones to last the tough mission without requiring a major repair. TALON robots were used extensively at Ground Zero in search and recovery efforts after the September 11 attack on the World Trade Center. They were the first robots taken into Afghanistan during action against the Taliban and Osama bin Laden. In four years, they performed over 20,000 separate assignments.

UGV use, which was once mainly focused on explosive ordnance disposal, appears to be shifting somewhat towards addressing chemical, biological, radiological, nuclear, explosive (CBRNE) threats and being weaponized. This article describes some Weaponized Multi-Utility UGV systems.

Weaponized Military UGVs

Weaponized robots handle almost all types of missions being developed for combat, where they can be deadly and perform dangerous missions. They are designed expressly for reconnaissance, surveillance and target acquisition missions. UGVs can bring superior over-match firepower to the enemy with heavy machine guns, grenade launchers and even anti-tank weapons, remote-operated by one or two soldiers. Military robots use sensors and can respond automatically.

“Transport of casualties”—THeMIS (Tracked Hybrid Modular Infantry System) is a fully modular hybrid UGV. This vehicle can be used for a very wide variety of applications starting from simple transportation to advanced weapon systems. (MILREM ROBOTICS)

MILREM ROBOTICS

MILREM ROBOTICS’ primary focus is in the manufacture of UGVs, development of robotic warfare solutions and performance concept of operations and doctrine level warfare analysis. The Estonian company, established in 2013, has roots from a group of Estonian companies dating back to the 1990s. Estonia is a NATO member country.

MILREM ROBOTICS claim that the company’s THeMIS (Tracked Hybrid Modular Infantry System) is the first fully modular hybrid UGV in the world. The electric drive with a diesel engine generator enables driving in silent mode while approaching intended areas. This vehicle can be used for a very wide variety of applications starting from simple transportation to advanced weapon systems. THeMIS is intended to reduce the number of human troops on the battlefield and assist or replace people that have to work in other high risk and dangerous work environments. THeMIS is remotely operated, and later, it’ll be equipped with an autonomy kit that allows the vehicle to drive with minimal operator assistance, i.e., between waypoints.

A similar combined system was already deployed successfully at the largest Estonian military exercise, Spring Storm 2017, and during a live firing demonstration in front of international military delegations in December 2017. THeMIS can provide support for dismounted troops by serving as a transport platform, remote weapon station, IED detection and disposal unit and much more.

MILREM THeMIS Weaponized with RWS

Generally the Remote [Controlled] Weapon Stations (RWS) are designed for tactical vehicles in order to provide optimized remote firing capability while keeping the operator completely under armor protection. THeMIS can be weaponized with various RWS, including:

• FN Herstal deFNder Medium;
• Nexter OPTIO-X20;
• KONGSBERG PROTECTOR; and
• ST KINETICS ADDER.

deFNder Medium

The deFNder Medium is the medium weight RWS of the FN RWS family. It can integrate all FN Herstal machine guns up to .50 cal., including the .50 Cal FN M2HB QCB or the 1,100 rounds/min. firing-capable FN M3R by FN Herstal.

Nexter OPTIO–X20

The OPTIO-X20 is the weaponized implementation of Nexter’s “New range of Multimissions Tactical Robotic System.”

At Eurosatory 2018 it was displayed on the MILREM ROBOTICS THeMIS. Runtime on the hybrid is 8h to10h. Silent run electric is 0.5h to 1.5h. OPTIO-X20 is armed with the ARX 20 RWS, its 20mm automatic cannon and 7.62mm, both gyro-stabilized.

ARX 20 RWS is able to handle up to Level 4 protected targets (a target that its armor protects to withstand 14.5x114mm AP/B32 at 200m with velocity 911 m/s).

The Turkish UKAP UGV. (Aud Håland)

MILREM ROBOTICS THeMIS with KONGSBERG PROTECTOR DUAL RWS

The THeMIS had been mounted with a PROTECTOR Dual RWS armed with a .50 cal. M2 and a Javelin anti-tank missile. This RWS on the THeMIS had not been live-fire tested at time of writing (June 2018), but it should be. KONGSBERG is the world’s leading provider of RWS. The PROTECTOR Family of RWS are systems suitable for any mission whether on land or at sea, on mobile or static platforms for remote operation payloads ranging from small caliber weapons to medium caliber automatic cannons. The system is modular, and all of the different variants of the PROTECTOR RWS share the same baseline technology. Three quarters of all the weapons stations KONGSBERG have produced are on American vehicles and have been used in the U.S. Army in one form or another since 2001. The fully three-axis stabilized PROTECTOR Dual RWS has the coaxial weapon mounted on the same axis as the main weapon. The system automatically compensates for the parallel axis between the sights and the axis. Switching between weapons is simply done by pushing a button. The ballistic calculations for both weapons are automatic. With an AGL, programmable ammunition can be used. The day and night sensors have high performance quality.

ST Kinetics ADDER

At Eurosatory, held June 13-17, 2016, ST Kinetics (Singapore) and MILREM ROBOTICS (Estonia) showed for the first time a live demonstration of the weaponized UGV THeMIS with the ADDER RWS. The ST Kinetics’ highly-capable ADDER RWS with the CIS50 MG. The CIS50 has dual gas pistons and a dual-feed system to quickly switch between types of ammunition. The ADDER incorporates auto-stabilization, tracking, thermal imaging and advanced sensors. The ADDER can also accommodate an M240 7.62mm MG or the CIS-40 AGL with air-bursting munition. The THeMIS has a maximum payload of 750kg–1,000kg and can handle the dual-weapon version of the ADDER.

Weaponized UGV from Turkish Katmerciler

The UKAP (Uzaktan Kumandali Atis Platform) UGV was developed primarily to provide close fire support in battle-intense environments. The chassis can move without difficulty in rough terrain and can climb up to 45 percent of the slopes. Despite having a weight of 1,100kg, it can carry loads as much as 1,000kg. All functions can be controlled by a remote control with a 10-inch LCD touch panel. UKAP can speed up to 25 km/h and run continuously for 5 hours. With the help of generators, this time can be upgraded to 8 hours. The main drive system of the vehicle, which has electric and hybrid models, consists of hydraulic motors powered by electric motors.

The version displayed at Eurosatory 2018 had a Stabilized RWS with a .50 cal. M2 machine gun. The RWS can also be equipped with a 40mm AGL or a 7.62mm MG. Remote Control Kit contains: LCD 10-inch Touchscreen, 5 hours continuous operating ability, Proportional joystick control, working temperature -25–+50o C, and all functions of UKAP can be operated remotely. Fire-on-the-move capability, day and night imaging–automatic target tracing, laser range finder for accurate ballistics, last round warning, manual back-up. At least 20 UKAPs (Remote Controlled Shooting Platform) will be delivered to the Turkish Armed Forces.

Rheinmetall’s new Mission Master UGV. (Aud Håland)

Rheinmetall’s Multimission UGV (MMUGV)

The MMUGV solution allows various mission profiles, from MULE to force protection and surveillance, using a variety of modular payloads. At the DSEI 2017 exhibition, Rheinmetall displayed its Force Protection Solution with double armament RWS. The Canadian-made Argo 8×8 was the basic chassis for Rheinmetall’s MMUGV.

Rheinmetall Mission Master UGV

Unveiled at Eurosatory 2018, this entirely new UGV was ready for the market. It had been developed for almost 18 months, and it is a modular concept. The Mission Master features long-range endurance with a silent electric drive. The configuration is cargo, surveillance, protection, rescue CBRN detection, fire suppression and communication relay. The Mission Master UGV has a high level of autonomy which allows the vehicle to be given a task. Its cargo weight’s capability is 600kg. The Mission Master base platform is designed to support dismounted soldiers. On a single charge, it can run continuously at 30km/hour with a 600kg payload for 8 hours.

When equipped with the optional generator, it can support a typical dismounted operation for more than a week. The Control Unit is very advanced, and the UGV can also be operated using the German IdZ-ES or ARGUS Soldier System for the Canadian Armed Forces as part of the network. The UGV is equipped with four LDAR radars for precision navigating in terrain, avoiding obstacles and entering in very narrow places. It can be air transported as slung load (CH53, V22 and Chinook as internal load), and it has amphibious capability with a maximum speed of 5km/hour (payload 300kg). Mission Master can be weaponized, for example, with the Rheinmetall Fieldranger RWS family. The weapon can be used with a machine gun up to a 20mm cannon or up to four anti-tank missiles. The displayed RWS was the Fieldranger Multi.

The Uran-9 UCGV is equipped with a wide range of remote-controlled sensor modules such as laser warning system and electro-optic and thermal imaging cameras. The onboard fire control system consists of automatic target detection, identification and tracking devices and a ballistic computer. (VITALY KUZMIN)

RS2-H1 SMET Robot

After 2 years of rigorous testing and a final 60-mile jungle march through the toughest Georgia swamps and jungle type terrain, the RS2-H1 SMET was able to lead with an average speed of 2mph all while carrying 1,000 pounds. RS2-H1 SMET robot has officially been selected by the U.S. Army. It has been noted by the U.S. Army that the RS2-H1 is the only Tracked Robot tested that is robust and durable enough for immediate service as the U.S. Army’s first platoon load-carrying robot. RS2- H1 SMET is a mid-sized, high torque, electric drive diesel hybrid “pack-bot” designed to operate in the toughest of terrains while offering unprecedented range, reliability and mobility. By incorporating state-of-the-art electronics and hybrid technology, the RS2-H1 exemplifies the most energy-efficient tracked “pack-bot” on the U.S. market.

YUGOIMPORT UGV

The remote controlled vehicle is designed to destroy and incapacitate single or group targets at a distance of up to 800m. The vehicle itself and the weapons are fully controlled from a remote and safe place.

The System Control is wireless. The Observation/Sighting equipment consists of FOV camera, narrow FOV day camera, thermal imager and laser range finder.

The Uran-9 Unmanned Combat Vehicle (UCGV)

The Uran-9 combat UCGV was unveiled by Russian manufacturer JSC 766 UPTK in September 2016 in Russia. The combat vehicle is based on a tracked chassis. The vehicle is designed to provide remote reconnaissance and fire support to a variety of tasks like counter-terrorism, reconnaissance and support for military units in urban environments. Fitted with a variety of weapons and sensors, the robot will improve the combat effectiveness of the infantry squads.

The Uran-9 system consists of four unmanned ground vehicles, one mobile command station and a truck for transportation of robots. The Uran-9’s remotely operated turret mounts different light- and medium-caliber weapon and missiles, based on mission needs.

The Uran-9 can be operated in either autonomous or manual mode. In autonomous mode, the vehicle can automatically identify, detect, track and defend enemy targets based on the pre-programmed path set by the operator. The vehicle uses detour path finding for obstacle avoidance in the autonomous mode. The Uran-9 UCGV is manually controlled by a single operator from a mobile command and control station mounted on a 6×6 tactical truck from a safe distance of 3km. It can also be controlled by means of a portable control panel in the manual mode. In addition, the vehicles are capable of moving autonomously in a column.

YUGOIMPORT UGV. (Aud Håland)

Conclusion

Unmanned platforms (from robotic vehicles on the ground to drones in the air and sea) represent a capability extension in many areas. The range of use extends to the use of weapons. Success on the battlefield now and in the future relies on the skilled leaders and soldiers as well as the use of advanced technology. In the coming years, there will be continued research in autonomy, machine learning, AI, power management and common control to achieve more capable UGVs and UAS. The primary focus will probably be improvements in situational awareness, soldier load reduction, sustainment and maneuver. In the long term, antiquated autonomous systems will be displaced and new robotic and autonomous systems fielded.

Technical Specifications A

Technical Specifications B

Technical Specifications C

Technical Specifications D

Technical Specifications E

Along white, sun-burned hilltops outside the city of Modi’in, snipers from around the world convened in July at Camp Adam to compete in the 5th annual Israeli Defense Force sniper competition. This was the first year of the competition that had competitors from different nations compete alongside IDF’s best and brightest combat tested snipers.

The IDF sniper competition isn’t your ordinary competition. Each stage is meticulously planned to emphasis the skills needed to succeed at combat; for with every passing day, the IDF is deployed along the borders of Israel, protecting their homeland from those who wish to do harm upon the state of Israel. The IDF’s mission is to defend the existence, territorial integrity and sovereignty of the state of Israel; to protect the inhabitants of Israel and to combat all forms of terrorism which threaten the daily life of Israelis. The IDF is built upon the principles of speed, aggression, and audacity. A sniper commander who is in charge of a three-man sniper team, does not expect the luxury of being able to appeal for instructions to higher command. He is on his own and his training allows him make decisions in the field without hesitation.

The counter-terrorism school located at Camp Adam was founded in 2012, and is divided into three sections: counter-terrorism, marksmanship, and sniper training. It trains both elite soldiers and ordinary infantry forces. Its staff members instruct others in combat, but also take part in counter-terrorism missions themselves on a regular basis. The IDF use their snipers in three distinct roles and applications; infantry, reconnaissance and counter terrorism operations.

A member of the Canadian JTF2 unit scans for targets.

The role of the infantry sniper has them operating as part of an infantry company or platoon. The sniper patrols within the formation with a patrol rifle and carries a sniper rifle in their pack. The sniper serves in the role of a rifleman until the need arises for the sniper to deliver long range accurate fire. This need may present itself in the form of harassing fire by the enemy from a distance that exceeds the maximum effective range of the patrol rifle. The sniper can also be used in sentry positions or in support by fire positions during the assault. The capabilities of the IDF infantry sniper is to deliver long range, precision, and discriminate fires, therefore minimizing potential collateral damage.

The IDF uses their snipers in a reconnaissance role similar to the way the U.S. military does. The biggest difference is the employment and use of camouflage by the sniper. Rather than training in ghillie suits or concealment hoods, they will employ thermal defeat blankets and carry decoy devices that mimic their surroundings. In the U.S. Army for example, they train their sniper to blend in with their backgrounds by utilizing negative space and obscuration. The IDF will employ those techniques but will also use geometrically shaped camouflage devices i.e. the Zikitec Cobweb, to simulate a rock. This use of the positive space allows them more camouflage possibilities.

The counter terror (CT) role of a sniper usually falls within the responsibility of the IDF Special Forces. In a CT formation the sniper is part of an intervention team. This team is comprised of one commander, two to three marksmen, two breachers, one machine gunner, one dog handler, one medic, one sergeant, three rifleman, and two snipers. The goal of the intervention team is to respond to a terror attack or high-profile situation and then isolate the area. The CT sniper is trained to take highly accurate incapacitation shots in order to free hostages or eliminate embedded hostiles. They carry the additional mission of protecting the borders in areas such as the West Bank. To accomplish that mission, they employ an accurized Ruger 10/22, which is a .22cal rifle. This accurized “less lethal” weapon is designed for taking knee cap and below shots.

United States Army Sniper Course Instructors finishing up the last night stage of day two of the competition.

Lying like lions in the sand, who at any moment, are ready to attack, nine three-man sniper teams from seven different nations, and thirty-two three-man teams from the IDF Infantry, Reconnaissance, and Special Forces battled it out in an intense three-day competition to crown the winner; champion of champions. The events of the competition aimed to depict operational situations which are relevant to combat snipers.

DAY ONE

After receiving the welcoming brief from the Sniper Department Commander of the IDF, competitors were assigned to squads, as this facilitated in less wait times between each stage, as each squad went off to separate stages, then switched once that stage was complete. Day one consisted of; two day stages and one night stage. The first day stage was an unknown distance stage that had competitors engage three human size steel targets at unknown distances from inside a building, in which the competitors had to build a stable firing platform and engage the targets through a window. One of the unique challenges of the competition was the team structure. In the IDF, they employ a three-man team consisting of; a shooter, a spotter, and a commander. Both the shooter and spotter utilize sniper rifles, and the commander carries a patrol rifle and is the one who authorizes the use of force and assists in spotting for each team member. For some of the international teams, they had to adapt to this team structure and work together to be successful. After engaging the unknown distance targets, the sniper teams exited the building and ran roughly 100 meters to a large dirt berm and had to engage a moving target that was being suspended by a drone. An Israeli defense company has been working with the IDF sniper department in creating a portable, and dynamic moving target for training purposes. The drone being used was of commercial size and had an average flight time of 45 minutes. The drone is able to travel along varying terrain and suspend a target that the snipers can engage. The drone operates off GPS and is able to move from point to point as deemed by the operator. The varying speeds and changing of directions were a humbling experience for each sniper team, but as the teams came off the firing line, they all agreed that it was a great device that mimics the lifelike characteristics of a human target; who runs, jumps, and takes cover on the battlefield.

The night stage of day one was a test of the team’s ability to quickly find four targets at various ranges, some of which were partially obscured by cover, and engage each target with only two rounds in six minutes. The catch was that the sniper team had to engage the targets while firing from behind a window and from a shooting tripod. The windows were small, and it forced the teams to adapt and precisely communicate with each other by voice commands and the use of their infra-red lasers. Teams that were able to quickly find the targets and illuminate the targets with their IR lasers and IR floodlights were the most successful. After the completion of day one, it was Israeli’s Maglan unit in first place, United States Army Sniper Course in second, and Israeli’s Shayetet 13 rounding out third.

Members of Israel’s Maglan Unit. Sniper is using a Barrett MRAD chambered in .338 Lapua.

Sayeret Maglan

Sayeret Maglan is an Israeli special forces unit which specializes in operating behind enemy lines and conducting deep reconnaissance in enemy territory. These elite members have gone after some of the worst terrorists in the West Bank and Gaza strip. Maglan was established in June 1986 as an elite unit specializing in anti-tank warfare using advanced weapons and is part of the Commando Brigade. During the Second Lebanon War, Maglan operatives oversaw the destruction of Hezbollah command sites, caches of ammunition, vehicles, and infrastructure.

Shayetet 13

Shayetet 13 is a unit within the Israeli Navy and is one of the primary special operation units of the IDF. The Shayetet 13 specialize in sea-to-land incursions, maritime intelligence collection, hostage rescue, counter-terrorism, and vessel boarding. Service in the unit combines long and comprehensive infantry training with specialization in marine warfare, diving, and the operation of special vessels. The unit has won Israel’s Chief of Staff’s award several times for its contribution to fighting terror and for developing innovative operational capabilities. The unit has participated in every war Israel has fought in, and are some of the most battle-tested men in modern times.

DAY TWO

Day two would be the most strenuous and exhausting day for the competitors as there were five day stages and two night stages. The hardest day stage for the competitors was the patrol stage. This stage had the entire squad of competitors (groups of ten) move as one unit over hilly terrain, in which they would come to a firing point and be given a time limit and the position that they could shoot from. At every firing point, there were three target lines for the competitors to shoot at. Two of target lines were stationary steel targets and the third was a row of popper targets that would expose themselves for only a few seconds at a time. Competitors had to engage the steel targets in sequence then engage the pop-up targets. As the sun rose over the sun-bleached hilltops, each team was feeling the pressure to perform. The teams that did the best were the ones who rehearsed setting up their equipment in a timely manner and who communicated in clear and precise instruction to the shooter, who waited feverishly on the spotter and commander to range the targets and make a wind call.

One event that didn’t consist of firing a single shot was an observation drill that challenged the sniper teams in target detection. This event tested the sniper’s ability to locate, identify, and record five military items that were hidden in a mocked-up village. The teams had ten minutes to complete the event, with points given for time and for items found. Target detection is a critical skill of the sniper. Snipers must locate, identify, report, and respond to critical information that they might encounter on the battlefield. Accurate reporting, and visual control over an enemy area is paramount to the success of the mission.

Israeli Snipers ready to engage targets at unknown distances through the window.

DAY THREE

The final day of the event had only one stage, and with the top competing teams vying for that coveted first place finish, pressure was building up and the teams that could focus and execute came out on top. The final event simulated a sniper team setting up a position in a confined urban area, similar to an alleyway. The teams had to enter a structure and engage moving and stationary targets out to 600 meters, but the caveat was that the sniper only had a limited field of view and the spotter and commander had to communicate with the sniper when a target popped up or when it was moving back into their field of view. If that wasn’t enough, the targets were being exposed behind plywood structures that the school cadre built, so the sniper teams had only a few seconds to engage the targets before the target went back behind cover.

After the dust had settled, scores were compiled and the IDF Sniper Department was ready to announce the top teams. In third place was Instructors from the United States Army Sniper Course, in second place was members of the United States Navy Seals, and in first, members from Israel’s Maglan unit.

The IDF International sniper competition was executed flawlessly thanks to the many reserve and active duty Soldiers of the IDF. All the men and women who helped make this event possible deserve the upmost admiration. A quick description of what it takes to be an elite IDF sniper instructor is that all sniper instructors complete a two-and-a-half-month course which is specifically for sniper instructors. The majority of the female instructors complete a two-month course which trains them to be Infantry Unit Instructors. As for male instructors, the majority come from a background of combat training, and most have completed an intense one-to-two year-long training path. Those instructors both instruct courses and are also active operationally. They are part of the IDF Sniper Department’s Sniper Squad who take an active role in the West Bank and Gaza strip.

Over the course of three days, these instructors embodied the professionalism of what the IDF stands for and every competitor left there with lessons learned and new friendships formed. Toda Raba!

NDIA’s Armament Systems Forum provides the U.S. and International Allied Armament government and industry framework understanding of the evolving global requirements and capabilities. The forum agenda communicates the trends in armament systems and technology which are shaping the enterprise today and in the future. Speakers, presentations, exhibits and demonstrations are planned to enable communication, networking and collaboration to seek solutions to challenges in systems, technology, manufacturing and warfighter application.

The primary purpose of the forum is to provide attendees content that will shape the evolution of new capability to ensure readiness in the complex world environment. Forum participation is focused to strengthen the government–industry partnership across the full life cycle, from requirement to fielding.

The Division’s activity is directed through three very active components: Small Arms Committee; Guns, Ammunition, Rockets & Missiles Committee; and Unconventional Emerging Technology Armament Systems.

Objectives of the Armaments Division are to:

• Provide focus on integrated armament systems including those used by individual soldiers; utilized on crew-served systems; and integrated into land, sea and air platforms.
• Provide assessment of current armaments and a vision of emerging military equipment and operational capability applying advanced technology in total armament systems.

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Mr. Jordan Progar of Barrett Firearms briefing the attributes of the Barrett .308 Win magazine to Cdr. Jens-Tore Alfei from DLO, Land Systems, Norway.

Col. Wesley Hallman, USAF (Ret.), NDIA Sr. VP of Policy is presenting NDIA’s Policy Vision to attendees at the 2018 NDIA Armament Systems Forum.

John Pollock, Dir. of Military Programs at Lancer Systems, explaining the performance characteristics of the Lancer Magazine to an attendee at the Forum.

Mr. Dave Stouffer, GD-OTS Business Development Manager, explaining the features of the GD-OTS .338 Medium Machine Gun to attendees in the Exhibit Hall.

This will be the 8th Biennial Tri-service event in Jakarta, Indonesia; when they say “Tri-service,” it means that they combine a number of shows into the one event. IndoAerospace, IndoMarine and IndoHelicopter are at the same site, with complementing events.

SADJ considers Indo Defence one of the top three shows in the Southeast Asia region, along with Defence & Security in Bangkok and Defence Services Asia (DSA) in Kuala Lumpur. These shows are on a schedule in alternate years and in the case of DSA, alternate time of year, so that vendors attempting to reach customers are assured of attendees who are not suffering from show burnout. Likewise, the attendees have the opportunity to see fresh presentations and products.

The people of the Republic of Indonesia take this show seriously—attendance is up all the way through the military and related sectors.

Many countries have pavilions in the expo’s six areas of the show.

There are live vehicle demonstrations and trips to foreign government warships. All through the show, events are concurrent with the open pavilions. Since the flow of attendees can be over 22,000, there is a constant movement of people through the display floor regardless of any other attractions. Most of the attendees are from Indonesia, and they take this show very seriously; the others are divided between many different countries.

While the various seminars and panel discussions are of great interest to the attendees in their various fields, for some the action will be on the show floor.

Small Arms Defense Journal was granted a unique interview with Textron Systems about the company’s most recent developments with the Lightweight Small Arms Technologies (LSAT) program that the U.S. Army Program Executive Office is currently running. Speaking with Wayne Prender, the current Vice President of Applied Technology and Advanced Programs from Textron Systems, we were able to shed some light on one of the more advanced small arms development programs of today.
Small Arms Defense Journal: How are things going with the LSAT Program?

Wayne Prender

Textron Systems: Along with some other competitors that are competing in the program, we were recently awarded a 12-month prototype contract. That award came on June 25 (2018), and we’ve been very excited about it. We will be producing one prototype and delivering that to the Army a year from now (Fall 2019). This product is a continuation of LSAT. Since 2004 we’ve been working on maturing and improving upon our cased telescoped (CT) ammunition that is a component of this program. One of the Army’s modernization priorities has been soldier lethality, and this is one of the first contracts to have been put in line with this. We’re very excited to be providing the Army with a system that is capable of not only meeting the objectives they have but also the growth that is necessary to enable a generational weapon to grow with the Army. We do believe that we have a very good technical approach, and a very good team assembled to complete this work.

SADJ: Right now the focus is on replacing the M249 SAW, but ultimately one of the goals of this is to produce a family of weapon systems, such as a rifle, carbine and designated marksman’s rifle, all at the squad level?

TS: That is correct, not just ourselves; the Army has laid out the plans for a family of weapon systems. We will continually optimize our prototype not only for the automatic rifle but also for a potential carbine version. Last year at AUSA we did release a carbine version of our CT Weapon, and we’ll continue to evaluate how to best improve upon that system for the future. Of course we also are looking at the family of belt-fed machine guns, whether they are light, medium or heavy machine guns. Something that we have incorporated into our design is that it is scalable depending on the operational requirement.

SADJ: Seeing that the Marine Corps has had a controversial switch to the magazine-fed M27 IAR, is there an interest in a magazine-fed SAW for the Army, essentially a magazine-fed LSAT?

TS: Right now there is nothing about the CT Weapon that makes it belt-fed only. In fact our carbine version is of course a magazine-fed system. We can go with either should the requirements change. But we are also not unveiling our particular design for the prototype; we are evaluating and going through the trace studies to determine what the best approach is to meet the Army’s stated requirements as well as their goals and objectives. Both configurations (belt-fed and magazine-fed) will be a part of our evaluation.

SADJ: Is there any possibility of an interchangeable feed system being implemented, such as was used with the Stoner 63 designs?

TS: No, I do not believe that is a solution set that we are exploring at this point in time. It would be overly complicated for a 12-month program. Again, we are primarily focused on showcasing the capabilities of the weapon and fire control system.

SADJ: Could you expand on the ammunition that you are using for the program right now?

TS: Cased telescoped is the technique of embedding the round into the overall cartridge of the ammunition. We do continue to use a polymer material to form that case. That provides a lot of technical advantages, but it also decreases the overall weight of the ammunition, in addition to the actual weapon system. We’ve also developed new techniques for firing this cased telescoped ammunition. As a result we’ve been able to reduce the overall weight of the system and improve its maneuverability, accuracy and, ultimately, the lethality. Really the prototype competition is about that lethality requirement. Currently we are focused on meeting or even beating the Army’s objectives with respect to performance as well as overall size and weight.

SADJ: Previously Textron Systems had been experimenting with caseless ammunition, but that appears to have stopped?

TS: Caseless development has actually not been dropped; we continue to explore caseless ammunition through a variety of contracts, but that is not at a state of maturity where the cased telescoped polymer ammunition is today. The Prototype Opportunity Notice (PON) does require a certain level of maturity and technology-readiness level. Our polymer cased telescoped ammunition and weapon systems do have that maturity. But in the meantime we continue to do research and development not only on caseless but other advanced small arms technologies.

SADJ: With the polymer cased telescoped ammunition, could you talk about some of the challenges in development?

TS: Anything new of course comes with some of its own unique challenges. But in the case of polymer cases, polymer actually provides a number of advantages. We cannot comment on some of the issues we’ve had, but we can discuss the advantages that we’ve come across. Not only is there a weight saving but quite honestly it is also strength of the case in addition to ease of manufacturability. Now, that may sound odd that the strength of the plastic is in fact better than current brass, but in conjunction with the weapon and how the weapon operates and handles that ammunition, the polymer cased telescopic ammunition is in fact a better solution than a conventional brass setup. It really isn’t about just the ammunition or just the weapon system; it is a system of systems that has to interact together. With that we’ve been able to make it successful. Obviously challenges occur on any development program, but obviously we’ve had 14 years of lessons learned on this type of weapon system. We’ve spent a large amount of time learning to develop weapon systems like this.

SADJ: Should LSAT and cased telescoped ammunition be successful, is there any avenue to converting current U.S. Army small arms into the system?

TS: Because of the way the ammunition and the weapon interact there really isn’t any feasible way to convert a standard brass-cased 5.56 or 7.62 chambered weapon system into a cased telescoped platform. While they look similar from the outside, function exactly the same from a user’s perspective to include firing and clearing, the internals of the weapons and how it handles [sic] is just too drastic to convert from the older platform to the newer.

SADJ: What is the next hurdle/step for Textron Systems down the line?

TS: We continue to execute the programs that we have on contract today. They are very critical and important contracts. This PON is the next step for the Army’s Next Generation Squad Automatic Rifle Program, and we are laser-focused on that.

Cased Telescoped Weapons and Ammunition
(Being developed in Hunt Valley, MD)

Game-Changing Weight Reduction

Textron Systems has a long, proven history as a designer and manufacturer of armament and ammunition technologies, having been involved in many Army small arms development programs over the past 50 years. The LSAT has undergone Military Utility Assessment (MUA) with the U.S. Army Maneuver Battle Lab, evaluation with U.S. Special Operations Command, and completed the Dismounted Non-Network Enabled Limited Objective Experiment with the U.S. Army Capabilities Integration Center (ARCIC).

Textron Systems oversees an experienced team of companies for the program including: ARES, Inc. of Port Clinton, OH; Orbital ATK of Independence, MO; General Dynamics company St. Marks Powder of St. Marks, FL; MSC Software of Santa Ana, CA; and Battelle Memorial Institute of Columbus, OH.

The next generation of CT weapons and ammunition systems delivers improved maneuverability and performance at 40-percent less weight than current systems. CT weapons and ammo are offered in a 5.56mm CT Light Machine Gun (LMG), a 7.62mm CT Medium (MMG) Machine Gun and a 6.5mm CT Carbine. Numerous military assessments and technical evaluations of our 5.56mm CT LMG have validated system maturity, performance and weight reduction benefits. These proven benefits are also present in the 6.5mm and 7.62mm CT systems. When it comes to equipping the warfighter, less is definitely more.

• Cased Telescoped Weapons & Ammunition
• Carry more ammo while reducing the load
• 5.56mm LMG proven to Technology Readiness Level 7
• Improves short-range engagement times
• Provides more first-round hits at long range
• Increases accuracy and maneuverability

We’ve all heard jokes about the government paying $1,000 for a toilet seat. Conversely, if you’ve served in the Army, then there has been a specialist somewhere who told you how your rifle was made by the lowest bidder. Or how about the one where your uniforms are stitched together by a bunch of blind people, tucked away in a lighthouse? Any of these stories and many more have come about because of the nuances associated with the bureaucracy that is Defense acquisitions.

We see the failures of this acquisitions system reported in the news daily—setbacks with the F-35 Joint Strike Fighter program; drop fires from the M17 Modular Handgun System pistols; heck, our Army has changed camo patterns three times in the last 15 years.

I understand the difficulty of making decisions on equipment when you have contracts that extend into the hundreds of millions or when said equipment must reach the hands of every soldier in the force. How can just a few people make decisions for so many? But, what I want to talk about is a much smaller community and its equipment. A community that, when employed, doesn’t rely on million dollar pieces of equipment. These soldiers operate in small teams, many miles ahead of friendly forces: the sniper and his rifle.

Here the M110 SASS can be seen with a Leupold Mark V scope, the newest offering of tactical scopes from the legendary optic maker. This version utilizes a Mil-grid reticle to maximize efficiency of follow-up shots.

As stated in the newly published Training Circular (TC) 3-22.10, “The sniper’s ability to engage point targets with accuracy at long range with minimal risk of collateral damage makes them useful in all levels of conflict. Snipers’ observation training, long-range optics and communication skills make them valuable tools for information activities.”

The sniper is a tool and a direct enabler. He provides his units with a significant asymmetric advantage over the enemy as a result of his flexibility, situational understanding and freedom of maneuver. When employed properly, the sniper provides the commander with overmatch. TC 3-22.10 describes, “Overmatch is the Sniper applying skills, employing their equipment, leveraging technology and applying the proper force to create an unfair fight in favor of the sniper.”

Currently, our military is going through yet another bureaucratic nightmare with choosing the sniper’s new rifle. A small team of engineers and program managers are working diligently to furnish a new rifle for today’s snipers. Seemingly they are doing so with little input from the men in the trenches. Don’t get me wrong, each of these men is intelligent with the best intentions at heart. But they are operating on guidance that was derived from a need of our snipers nearly a decade ago.

An early prototype for the CSASS program with upgrades such as a suppressor, a collapsible buttstock and a 16-inch barrel.

Times Have Changed

In the early stages of the war in Iraq, the sniper found himself in urban environments. The days of sneaking around the jungle looking for the VC commander and employing singular, well-aimed shots were a distant memory. Instead, snipers would sneak into a town under the cover of darkness and set up inside of a building. These conditions lead to short, quick engagements with target rich environments.

At that time, the sniper community was working with Post-Cold-War-era technology. The tried and true Remington .700 action in the form of the M24 Sniper Weapon System, topped with a Leupold Mark 4 fixed power scope. The M24 was a bolt-action 7.62mm rifle. Married with M118lr, 175gr match ammunition, it could deliver accurate fire to man-size targets at ranges of 800 meters. While accurate, this platform had its shortcomings. It was heavy, had a small magazine capacity and slow to reload.

Enter the M110 Semi-automatic Sniper System (SASS) by Knight’s Armament Company fielded in 2008. Knight’s had based their product on the SR-25 version of the original AR-10 designed in the ‘50s by Eugene Stoner. It was semi-automatic, magazine-fed, suppressed, had an adjustable length of pull and fired the same M118lr ammo. In addition, the Army had elected to have it outfitted with the Leupold Mark 4 with Tactical Milling Reticle in 3.5-10x40mm. Due to the rifle’s design with a free-floating handguard, a PSQ-20 night optic could be mounted in front of the day optic, eliminating the need to swap sights.

This new platform performed well but came with shortcomings of its own. It was heavy, weighing in at 15 pounds and 46 inches long. This meant clearing your way through a building enroute to your hide site was cumbersome and tedious. The suppressor with its overlapping design, reduced the length added to the end of the barrel but trapped heat. Couple this with rapid follow-up shots and the 100+ degree temperatures found in the Middle East, and barrel mirage becomes much more challenging.

Snipers utilizing the Army’s anti-materiel weapon also known as the M107 from Barrett. This shooter can be seen shooting the M24 Sniper Weapon System in Iraq.

New Compact Semi-Automatic Sniper System (CSASS)

Fast forward to modern day and the folks in acquisitions are finalizing decisions on the Compact Semi-Automatic Sniper System. This platform will have a redesigned suppressor, 16-inch barrel and collapsible buttstock. The real advantage to this system is its compact size.

Reception of the new rifle has been lukewarm at best. Its current layout keeps the same antiquated day optic and ammunition, while losing considerable accuracy at ranges past 600 meters. If you weren’t aware, 600 meters and beyond is where the sniper gains his relevancy over his Squad Designated Marksman (SDM) brethren. There has been some commotion about the new rifle being outfitted with a 1-8x optic and getting a new fielding requirement to be used as an SDM rifle. That is fine and all but raises two questions: what is the way ahead for an M110 SASS replacement? Also, if there is a need for intermediate range target engagements, why not employ the underutilized sniper, every Combat Arms Battalion already has? No need for a new rifle, additional training or manning.

In March 2018 the Special Operations community announced that they were going to move ahead with adoption of the 6.5 Creedmoor as the new sniper round. This adoption alone bridges the gap between the 7.62 Match ammo and .300 Win Mag currently being used, while offering a lighter recoiling round that travels faster and is less affected by wind. The Special Operations community has freedom of maneuver and the ability to reach out into the market to choose the weaponry and ammunition it deems best. But the conventional side of the force doesn’t have these privileges.

This scope and red dot combo exists in the Army’s supply system. Its features assist the sniper with easier wind hold, rapid target engagements and increased target identification. Unfortunately, it remains outside of the conventional sniper’s reach due to the quagmire of acquisitions.

One Size Fits All Doesn’t Work

The sniper community is small. Currently, snipers number less than 2000 and account for about 0.004 percent of the total Army manpower. With a community that small, there is no need for equipment acquisitions to be decades in the making.

The military needs to stop its “one-size-fits-all” approach to arming the sniper community. Each unit has a different mission and may require different equipment and ammunition. A commander in the 101st Airborne (Air Assault) may need his snipers to be able to effectively engage dismounted targets in the mountains of Afghanistan, while a commander in the 3rd Infantry may need to penetrate light-skinned armor reconnaissance vehicles.

Alternate components and accessories do exist within the supply system. Items such as the Mark 6 with Tremor 3 reticle from Leupold have been awarded a National Stock Number (NSN). The NSN is a numeric code applied to all items currently available with the Department of Defense supply system. The Mark 6 offers more magnification, a reticle pattern that facilitates rapid ranging, wind dots and a grid system for follow-up shots. Simple upgrades like this coupled with 6.5 Creedmoor ammunition would greatly increase the effectiveness of the sniper but remain unavailable to the conventional force.

Above and below: This Sniper has put together a formidable weapon system, utilizing the Leupold Mark V with H58a atop a 6.5 Creedmoor AR-10A Wilcox Raptar-S laser rangefinder and Advanced Armament Corp TiTAN-QD suppressor.

Snipers Need Options

What do the sniper and his commander actually need? Options. Establish a modular sniper system within the Defense supply chain that the commander can choose from. Within this system will be the full accompaniment of optics, rifles, ammunition, laser range finders and accessories that will allow them to choose a specific package that fits their mission set. One-size-fits-all approaches, while a necessity for the common force, do not apply to such a highly specific job.

Leupold’s newest tactical scope, the Mark V, featuring the Horus H59 reticle.

Leupold’s newest tactical scope, the Mark V, featuring the Horus H59 reticle.

Part Two described some unguided, shoulder-launched rocket weapons. Among these was the Panzerfaust 3 family produced by Dynamit Nobel Defence (DND) from Germany. Such shoulder-launched anti-tank weapons have turned into versatile multipurpose weapons, and new developments are ongoing. The purpose of this article is to describe the following products:

DND’s shoulder-launched Recoilless Grenade Weapon (RGW) 90 with multipurpose capabilities;
MBDA’s shoulder-launched Enforcer guided missile system;
Rafael’s shoulder-launched Spike SR (Short Range) infantry missile;
Javelin.

Upper: MNV-50 Night Monocular (~630 grams). Lower: Laser Optical Sight with LRF/Ballistic Computer (<1kg), RGW 90 family. (Aud Håland)

RGW 90

DDND GmbH has developed a new shoulder-launched weapon: the RGW 90. It’s designed to fill the gap between current shoulder-fired weapons that are capable of operating at ranges of 300–600 meters and anti-tank missiles.

The RGW 90 LRMP is a 90mm man-portable, anti-armor, multipurpose disposable weapon system. RGW is short for “Recoilless Grenade Weapon,” while LRMP describes the “Long Range Multi-Purpose” nature of the programmable warhead. It’s fully mechanical, has no power supply, recoilless and easy to handle. The RGW 90 LRMP has an effective range of 1,200 meters and is very effective against a variety of targets. The Dynahawk reusable fire control sight maximizes the first hit probability against distant targets by allowing the gunner to measure target distance and other relevant data in the visual field. The warhead, which utilizes a trimodal programmable warhead fuze, can be set before firing by the shooter for point (impact), short or delay activation—enabling the weapon to defeat light armored vehicles and field fortifications—or it can be set for airburst to defeat targets behind cover. The effector is a 90mm multifunctional warhead with an effective range from very short (20 meters) up to 1,200 meters, double the effective combat range of comparable weapons. Like other Dynamit Nobel Defence weapons, the RGW 90 LRMP is operable from enclosed/confined spaces, which is particularly useful for combat engagements in urban terrain. Thanks to its state-of-the-art in-flight propulsion system, the RGW 90 has an excellent hit probability. A standard interface rail allows a night sight to be fitted. The weapon can also be delivered with an illuminated sight to provide night fighting capability without the need for additional accessories. Featuring a non-electric firing circuit and several independent safety elements in the firing mechanism, the RGW 90 LRMP is safe to ship and handle under all environmental conditions. Its high-quality optical sight and balanced, ergonomic design help to increase the weapon’s effectiveness. A complete set of training equipment is also available for the RGW 90. The RGW 90 LRMP fulfills many of the tactical requirements of infantry units for a truly multipurpose tactical weapon. Procurement of the RGW 90 LRMP from Dynamit Nobel Defence began with the German KSK (Kommando Spezialkräfte) and Naval Special Forces. The infantry will subsequently be equipped.

The RGW 90 AS (Anti Structure) is specially designed to support troops in an urban environment. The tandem warhead with a Break-In Charge (BIC) and a Follow-Through Bomb (FTB) performs well against a variety of structures. The smart fuze of the FTB allows the gunner to choose between two modes: a “Blast” mode to detonate inside the building to remove its protective value and a “Mousehole” mode to create to create a man-sized hole. The high level of penetration offered by the combined BIC and FTB warhead also provides excellent performance against light armored vehicles.

The RGW 90 HH is a lightweight multipurpose weapon, capable of defeating tanks as the primary target and buildings or field fortifications as the secondary target. With its 90mm dual-mode warhead, the RGW 90 provides all these capabilities in a single, lightweight, disposable weapon at an affordable cost. RGW 90 features an excellent hit probability due to a state-of-the-art in-flight propulsion system and can be Fired From Enclosure (FFE).

Enforcer with sight system held by a British soldier. (Aud Håland)

MBDA Enforcer

Enforcer is a German-led, multinational MBDA program with the aim of providing a simple, quick and effective protection weapon for soldiers in action against a variety of threats. Enforcer is the answer to the need for a lightweight and high-precision weapon with standoff capability for infantry and Special Forces at an affordable cost. The Enforcer concept is a new, lightweight, disposable shoulder-launched guided munition in the 2,000-meter range class with high precision over the full range. Enforcer provides major advantages for infantry and Special Forces, bringing with it superior range and effect compared to heavy machine guns, Grenade Machine Guns and rocket launchers. Compared to previously used weapons systems, this small missile offers numerous advantages. It’s a lock-on-before-launch (LOBL) and fire-and-forget missile system with minimal exposure of the operator to enemy fire. Enforcer can be operated from behind cover and from enclosed/confined spaces. The weapon can be carried and operated by a single soldier (missile + launch tube <9kg). The system (sight and two munitions) weighs <20kg, and the missile weighs <7kg. It enables dismounted infantry to engage lightly protected battlefield and urban targets at relevant combat ranges beyond the capability of currently available infantry weapons. Enforcer can be used to engage a broad variety of targets, including lightly armored, static and moving targets, threats behind cover, soft-skinned targets (including concealed snipers) and infrastructure, with high precision and minimal collateral damage. The missile is effective against targets behind cover through its airburst capability, multi-effects warhead and ability to be fired from enclosed spaces. Enforcer has already demonstrated its technical maturity in several tests to prove the viability of the technology and design. Successful firing against moving targets and airburst trials at a range of 1,000 meters in 2017 followed three successful guided firing trials in November 2016. These demonstrations were carried out with a development model of the Enforcer at the Bundeswehr’s Technical Center for Weapons and Ammunition against stationary targets at ranges between 1,000 meters and 2,000 meters, using both an earlier steel launch tube and the new developmental carbon fiber tube. The firings were part of the proving trials for the missile’s LOBL EO homing guidance and also demonstrated a new, much lower flight trajectory in the missile engagement sequence and very high precision at all ranges. Data analysis of the firing confirmed that the seeker precisely detected and tracked the target for the entire flight of the missile. One of the areas MBDA is currently working on is the Bundeswehr’s night fighting capability requirement. MBDA plans to begin qualification and series production of this very compact missile over the next few years. In this respect, more guided firings are planned for 2018. Enforcer will be offered to the German Army. It will also be available in 90mm caliber, which could complement the RGW 90 LRMP infantry weapon. Enforcer’s modular architecture enables a range of future development options—preempting the anticipated evolution of military operations scenarios toward greater complexity—including the prospect of an Enforcer munitions family. Another advantage of the missile’s modular design is its potential for customization for different applications and platforms.

Enforcer with sight system (missile + launch tube <9kg, sight ~2.2kg). (Aud Håland)

Spike SR (Short Range)

A short-range, man-portable, shoulder-fired, fire-and-forget, electro-optical (EO) guided missile, Spike SR is the latest and most compact member of Rafael’s fourth- and fifth-generation Spike missile family.

The Spike family comprises such electro-optical missile systems as the Spike MR/LR (Medium Range/Long Range—maximum range 2.5 kilometers/4 kilometers), Spike ER (Extended Range—8 kilometers) and the standoff Spike NLOS (Non Line Of Sight—30 kilometers). The whole Spike family is operated by 29 nations, which have procured more than 29,000 missiles in the last 25 years. In addition, Rafael has unveiled the new Spike LR II missile (5.5-kilometer range) to meet today’s new operational requirements. Spike SR is optimized to defeat modern MBTs and APCs and to penetrate bunkers. It was designed as a very light multipurpose infantry weapon for use by the infantry platoon, infantry squad or Special Operations Forces. Unlike the aforementioned shoulder-launched rocket system RGW 90, Spike SR is a guided missile. The SR missile was tailored to the combat needs of infantry forces in contemporary and future conflicts. It is optimal for use in a large variety of operational and environmental scenarios against a range of conventional threats (including regular forces using established tactics) and unconventional threats (such as insurgents employing asymmetric tactics) worldwide. Spike SR is simple to use; the operation sequence involves four switches and responsive icons, as it was designed for the basic infantry. Spike SR has a short time interval from power-up to operational readiness. In less than six seconds the missile is ready to engage targets that are exposed only for brief periods. Unlike the gimballed seeker installed in the Spike MR/LR/ER (Medium-Range/Long Range/Extended Range) missiles, the Spike SR incorporates an uncooled and fixed dual day/night-capable EO seeker and tracker that offers lock-on and fire-and-forget capabilities against even fast-moving targets.

The Spike SR has a high hit probability against stationary and moving targets from 50 meters out to 1,500 meters. The short minimum range of only 50 meters came as an operational requirement from the multiple customers of the Spike family in NATO. Such a short-range capability could become important in forested battle arenas, where a tank target can appear suddenly between the trees.

The Spike SR missile launcher includes an embedded miniature Command Launch Unit (CLU) that, like the canister, is totally disposable after launch. This means there’s nothing to maintain, driving the LCC down. All the capabilities mentioned above are packed into a small (98-centimeter) and light package weighing a little less than 10kg (including the missile, CLU and battery). Spike SR’s operational simplicity provides the infantry soldier with the versatility and rapid response capabilities that are essential in modern conventional and asymmetric combat. The Spike SR was designed to give the infantry a low-cost, high-end solution, capable of destroying MBTs, as well as other targets, at less than half the price of modern ATGMs. The Spike SR has already been procured by several customers and is an off-the-shelf product.

Firing a Javelin. A battlegroup from Telemark Battalion on high-readiness exercise “Bifrost” in northern Norway (October 16–20). (Ole-Sverre Haugli/Norwegian Armed Forces)

Javelin

Javelin is a shoulder-fired, fire-and-forget, portable anti-tank missile. The missile system is most often carried by a two-person team consisting of a gunner and an ammunition bearer, although it can be fired with just one person if necessary. While the gunner aims and fires the missile, the ammo bearer scans for prospective targets, watches for threats, such as enemy vehicles and troops and ensures that personnel and obstacles are clear of the missile’s backblast.

To fire, the gunner places a cursor over the selected target. The Javelin CLU then sends an LOBL signal to the missile. With its soft-launch design, Javelin can be safely fired from inside buildings or bunkers. The missile is ejected from the launcher so that it reaches a safe distance from the operator before the main rocket motor ignites: a “soft launch” arrangement. This makes it harder to identify the launcher; however, backblast from the launch tube still poses a hazard to nearby personnel. Javelin’s long-wave IR seeker enables it to engage under conditions of reduced visibility and resist countermeasures. The team can reposition immediately after firing or prepare to fire on their next target while the first missile is still in the air. The system takes a top-attack flight profile against armored vehicles (attacking the top armor, which is generally thinner), but can use a direct-attack mode against buildings, targets inside the minimum top-attack engagement range and targets under obstructions. Javelin is combat proven, used by American forces in the Iraq War and in Afghanistan. In Afghanistan, American soldiers also used the Javelin against threatening insurgents firing from machine gun positions. Its versatility makes it effective against tanks, bunkers, buildings, small boats and slow-moving helicopters in the direct-attack mode. It can reach a peak altitude of 150 meters (500 feet) in top-attack mode and 60 meters (190 feet) in direct-attack mode. The tandem warhead is fitted with two shaped charges: a precursor warhead to detonate any explosive reactive armor and a primary warhead to penetrate base armor. Javelin has a wide range of effectiveness (from less than 75 meters to more than 2,500 meters), offers more tactical possibilities and has unmatched lethality; with a missile reliability level of more than 93%, its first-hit probability is over 94%. The Javelin system is adaptable to many platforms, including tripods, trucks, light armored vehicles and remotely piloted vehicles. Javelin is sold in Europe, the Pacific and the Middle East.

The Enforcer is also compatible with the Hensoldt (formerly Airbus Optronics and more formerly Zeiss) Dynahawk clip-on fire control system currently selected for the RGW 90 LRMP. (MBDA)

Spike SR has a rugged design and utilizes a versatile, lightweight (9.6kg), single-use disposable launcher canister (length 970mm). (RAFAEL ADVANCED DEFENSE SYSTEMS LTD.)

Longtime readers of Small Arms Defense Journal and Small Arms Review are probably aware of this author’s penchant for takedown, discreet firearms. High quality, accurate, effective, concealed DMR type packages that look innocuous and can be snapped quickly into action. One other focus has always been finding controllable, lightweight 7.62x51mm full autos. Yes, I was weaned on my beloved M16A1, and yes, I’ve tested, collected, trained with and used almost every 5.56mm rifle out there. They’re still all rifles with a restricted range and effect due to the cartridge, and in my heart I’m an old .30 cal/.45acp guy. After a lifetime of experience with FALs, M14s, G3s and countless other true battle rifles, I’m glad to see that the great-grandchildren of Gene Stoner’s AR-10 have been coming into their own of late as select-fire rifles. First, LMT and Law Enforcement International had their custom 7.62x51mm select-fire offering in Jordan, which evolved quickly into Great Britain’s current Designated Marksman’s Rifle, the L129A1 “Sharpshooter”—one hell of a rifle serving proudly and effectively in Afghanistan, but alas, no selector switch. Small Arms Defense Journal covered it in Volume 3, Number 3. Next, Patriot Ordnance Factory presented the P308FA, which Small Arms Defense Journal covered in Volume 8, Number 1. We were truly impressed with the small size, weight and amazing controllability of the POF offering. In Volume 9, Number 1, I covered the DRD Tactical Paratus takedown rifle, developing a whole backpack system for what I believe to be the best covert takedown DMR around. All of these articles are online at sadefensejournal.com.

Left side of Paratus select-fire rifle in a CQB configuration with Aimpoint Patrol Rifle Optic.

Now, it all comes home together, and I’m happy to present the following article—Skip Patel has made the great leap forward—the Paratus in select fire opens up capabilities that I’ve been watching for …

In this age of body-armor-wearing bad guys, improvised armored vehicles, extended threat ranges and just a general need to exceed the 5.56mm capability restrictions, 7.62x51mm is a quickly available alternative rifle round. While USSOCOM and others work to define a new round from 6.5 Creedmoor, .260 Remington and other excellent performers, that old .308 round is in TO & E system and available. It’s also a proven battle round. When I tested the Paratus rifle from DRD Tactical, the fact that a basic Covrt18™ backpack from 5.11 could conceal a true DMR was mind-blowing. I couldn’t help but wonder what would happen if those capabilities were augmented by having a reliable select-fire capability. As long as it didn’t compromise the DMR aspect, it was a desirable upgrade.

Recent conversations with Skip Patel from DRD Tactical (DRD stands for Defense Research & Development) indicated that he was approaching that capability and that he had used a G3 S-E-F trigger pack inside his lower receiver. Aside from all the interesting possibilities incumbent with that, the G3 trigger pack is a good, solid, reliable trigger system, and it is a good fit to the Paratus. This change means that the upper and lower receiver and bolt carrier for the select-fire Paratus are not interchangeable with the semi-automatic version.

Paratus PMG (Paratus Machine Gun) Specifications

When viewing the Paratus MG, two distinct uses come to mind almost immediately: first, the Paratus as DMR with a selector switch as a backup battle rifle; and second, as a CQB weapon. In both cases, the concealable nature of the design allows the operator to discreetly get into position for use. Fired in fully automatic, the rate of fire is 600 rounds per minute, and it is a natural cyclic rate for the rifle.

For our testing, I first wanted to accessorize these two variations properly. For the DMR I went back to Trijicon’s VCOG 1×6 for an optic: This was the optic chosen for the backpack Paratus DMR system SADJ previously covered. It’s such a good pairing, that I kept it for this testing. In the first Paratus test I used a Gemtech Quicksand suppressor. For this test I used the Elite Iron Bravo 1 suppressor; a robust and effective suppressor that has a unique attachment system which switches out to an efficient muzzle brake, has a variety of caliber uses and is full auto rated for .30 caliber.

Harris bipod: I generally use the Harris HBRS that has 6-inch to 9-inch extendable legs and add the Picatinny rail adapter as well as the “S” lock lever for cant. I’m not fond of the side-to-side swivel on this type of setup, it adds weight that I don’t find necessary, but the lever for the cant lock is fast, sturdy and fine-tunes the rifle to level quickly on rough terrain.

Live firing of the DMR version was performed with both Black Hills 175 grain Match Hollow Point with a velocity of 2600 fps and M118LR from Lake City, my basic go-to 7.62x51mm rounds. Both provide muzzle energy in excess of 2600ft/lbs. It’s already a known fact that Paratus performs well and returns to zero on re-assembly. The changes DRD made to go select fire had no effect on that. I was concerned there might be a reduction in accuracy from the original Paratus, this turned out to not be the case at all. Both rounds were well within 1 MOA performance.

Looking down inside the Paratus select-fire rifle’s lower receiver, the ubiquitous G3 trigger pack can be seen as a drop in unit.

How controllable would a DMR setup be on select fire? That is the real question here. The idea is to switch from long-range firing to engaging close in threats and be ready to do so with a flip of the switch. The VCOG optic is perfect for that—given a decent longer range firing and being able to switch to the Trijicon both eyes open firing with the same scope.

With everything mounted on it, it was a bit heavy. However, we’re not asking the DMR to become an M240 suppressing fire at 1000 meters; we’re looking at close in threats with burst fire. I found the full auto setting to be very easy to get two round bursts and keep them on target. Very fast to switch from long-range semi-auto to close engagement bursts. It’s another tool in the assets for a DMR operator, without having to keep a second rifle. Success on this.

Changing to a CQB Configuration

For a CQB use, basically keeping the option of a suppressor, removing the bipod and switching the optic for something lighter and faster were important. The Aimpoint Patrol Rifle Optic was a good choice for this. At 9.2 pounds plus the ammo and optic, it’s not an M4. However, the Paratus in select fire is capable of packing up extremely small in a discreet backpack and becoming a robust 7.62x51mm jackhammer. It’s not supposed to be an M4. My goal was to fire two round bursts on target, quickly, so the 30-caliber double taps would engage any reasonable target short of rolling armor. I might be exaggerating a bit on that, but the Paratus was fast, accurate, the 600 rpm cyclic rate was within the harmonic of the rifle, and it was reliable. DRD has a very strong contender for the takedown rifle with serious power.

In conclusion, the Paratus in a select-fire configuration is a success. It gives a lot of options to an operator—like any good descendant of the Stoner system, it has configurations that can be opted for according to need. This rifle should be in consideration for any special operations needs that require discreet insertion of a weapon system into an area, with accurate fire and the added capability that the fully automatic 7.62x51mm can bring to the equation.

FOR MORE INFORMATION

drdtactical.com
Eliteiron.com
trijicon.com
aimpoint.com
harrisbipods.com
black-hills.com

Right and left side view of the Paratus Select Fire with Trijicon VCOG 1x6 optic. Note the HK style selector lever and the fact that Paratus is left side charging.

Right and left side view of the Paratus Select Fire with Trijicon VCOG 1x6 optic. Note the HK style selector lever and the fact that Paratus is left side charging.

Paratus standard muzzle brake. Note that at arrow is gas adjustment nut for suppressor use. Middle: Paratus barrel with Elite Iron muzzle brake and cap. Bottom: Elite Iron Bravo 1 suppressor and Paratus barrel with cap removed from Elite Iron muzzle brake.

The author posing (thus no sight or hearing protection) with the Paratus select-fire rifle with Aimpoint Patrol Rifle Optic installed. In this configuration, the rifle, while heavier than many CQB units, has the firepower to overcome obstacles such as an adversary with body armor or hiding behind medium cover.

Right side of Paratus select-fire rifle in a CQB configuration with Aimpoint Patrol Rifle Optic and Magpul Adjustable Folding stock in folded position.

Aimpoint’s Patrol Rifle Optic was chosen for the CQB variant— it’s lightweight, robust and has a 2 MOA red dot and is very fast to acquire targets.

The BRAVO 1 tactical brake is available in 5/8-24 for .30 cal applications and 1/2-28 for .223/5.56 applications. Both include a cover cap for shooting without a suppressor. The 1/2-28 .22 cal brake allows the BRAVO 1 to be used on .223/5.56 weapon systems with no barrel length restrictions.

The takedown lever on the right side of the forend clamps the forend securely to the barrel nut; this provides repeatable performance. Once the lever is opened, the locating pin can be pushed out to the right.

The forend can then be removed to the front of the barrel.

This exposes the barrel nut. When the barrel assembly is put onto the rifle, the gas tube is located in the upper receiver hole, then the barrel is slid into place. The barrel nut is removed in this picture, using the spanner wrench supplied with the rifle. On installation, the torque applied should be 35ft/lbs. The spanner has a ½” socket square drive location for using the torque wrench. In reality, any operator will experiment and learn what approximately 35ft/lbs “feels” like and proceed accordingly. It’s important to hit that torque especially in full-automatic fire.

The barrel nut is removed forward and the barrel assembly removed to the front.

The barrel nut is removed forward and the barrel assembly removed to the front.

Right side view of the Paratus select-fire rifle as prepared to store in its pack.

DRD supplies a “Cup” that is threaded— the purpose is two-fold. First, it protects the threads of the barrel nut when disassembled. Second, it stabilizes the gas tube when disassembled— a very important step.

Removing the bolt carrier and recoil assembly is similar to the regular AR type, with a rear pushpin that exits to the right; however, there is an op rod that has two ears at the top of the upper receiver that must push in as well. There is a locating pin on the back of the op rod that locks into the lower receiver. This is all under spring pressure, so the operator should control the op rod and spring as the upper receiver is rotated upward.

Disassembled operating group showing the DRD Bolt group. This bolt group for the select-fire Paratus is different from the bolt group for the semi-auto Paratus; they do not interchange.

Paratus stored in its discreet hard case of 18x12x8-inch dimensions, with high density foam cut out to securely carry the rifle. Generally, deploying it is in less than 60 seconds.

Three almost equal in weight and punch

There is no faster and more delay-free fire support for dismounted fighting forces than from the machine gun man’s 7.62mm machine gun’s sustained fire. The correspondingly long range and effect in the target are the determining factors here.

Battle Proven and Reliable but Heavy to Carry

The M240 Machine Gun is the principal suppressive fire weapon for the infantry platoon and company. M240 series is used in the U.S. Army as the M240B, USMC and USN as the M240G, and as either “B” or “D” for USAF services. The M240B is one of the most essential and widely used small arms in Iraq and Afghanistan. The M240B’s weight unloaded is 27.1 pounds (12.3kg). Any soldier who has ever served as a squad automatic weapon gunner is resigned to the burden of lugging a heavy weapon and ammunition on patrol. The M240B offers absolute reliability, long range and exceptional service life, but its coaxial origins limit its ergonomics in dismounted role, length and weight.

Newer Concepts

Textron Systems, for example, has developed both weapons and cartridges to reduce soldier load by about 40 percent with machine guns in both 5.56mm and 7.62mm caliber with use of cased telescope cartridge in polymer casings. USSOCOM, in conjunction with the USMC, was in 2017 seeking sources within the national technology and industrial base with the ability to provide 5,000 units .338 NM belt-fed medium machine guns: a complete machine gun system to include weapon, suppressed barrel, tripod and any tools needed to conduct basic maintenance. The lightweight medium machine gun (LWMMG) should fire the belted .338NM round of ammunition with a polymer case. The LWMMG should weigh less than 24 pounds unloaded with a barrel length of 24 inches (Source: Federal Business Opportunities, May 11, 2017). The .338NM ammunition is heavy to carry, and that’s not what the squad’s automatic weapon gunner wants to carry on tactical movements. The .338NM chambered LWMMG would need a two-man MG-team.

The gas-operated MG5 offers numerous technical and ergonomic innovations.

Contemporary Machine Guns

The purpose of this article is to describe the three machine guns: MG5, 240LWS and M60E6.

MG5

The operations of the Bundeswehr (“Armed forces of Germany”), especially the mission in Afghanistan, had shown that there was an urgent need for the 7.62mm caliber class of medium machine guns. Bundeswehr’s MG3 machine gun is no longer able to meet the requirements of a modern machine gun, and it requires a lot of effort to keep it in use. Rheinmetall’s MG3 will therefore be replaced by a new machine gun. As part of the project “New Machine Guns,” the successor of the MG3 had to pass several test series.

The MG5 from defense manufacturing company Heckler & Koch (HK), the most prolific German weapons maker, was chosen as the successor to the MG3. The MG5 (formerly known as the HK121) is a general-purpose machine gun. The MG5 is gas-operated and chambered for the 7.62x51mm NATO round with M13 disintegrating metallic links. MG5 offers an intelligent and contemporary build standard, with numerous technical and ergonomic innovations with features like belt feed with loading indicator, cocking in all safety positions, and, with an adapter, it can be installed on all mounts and tripods originally developed for MG3 machine guns. The MG5 can be reconfigured to a mounted, universal, Special Forces or infantry machine gun, without special tools. It has a special buffer that reduces recoil forces and stabilizes the rate of fire and has an adjustable rate of fire (3-positions). When HK designed the MG5, special emphasis was placed on robustness, reliability, ergonomics and easy handling. The MG5 withstood barrel obstruction testing to NATO-AC225/D14 standards (soft core and steel core ammunition DM111A1, DM151). The result is a compact, medium machine gun, which is well-suited for dismounted infantry both by the weapon’s design and its fire superiority in combat.

Turning away from the system of MG3’s short, recoil-operated loading mechanism to the indirect gas pressure loader was a significant improvement in the shooting behavior of the weapon and improved hit results were achieved. With the MG5 it’s now possible to fire against targets from a standing firing position, an option that was impossible with the MG3. In the prone position, especially when using the riflescope, it’s possible to achieve accurate hit performance, which was previously possible only with the help of a tripod. For a medium machine gun, this is a very considerable precision.

The weapon’s operation is almost similar to that of the MG4 light machine gun. The safety and three-position fire rate selector levers are ambidextrous, the butt stock can be folded depending on the variant, and numerous Picatinny rails allow installation of optical sights and other accessory options for aiming aids such as optics/optronics, laser/light modules or clip-on thermal scopes. The quick-change barrel has a heat shield and a carrying/barrel exchange handle. A hot barrel can be replaced without protective gloves. The iron sights consist of a collapsible front sight and a height and windage adjustable rear diopter sight. The charging handle is on the right side of the weapon. For feeding, 50-round belted ammunition pouches or 120-round belted ammunition boxes can be mounted on the left side. The MG5 can be installed on all mounts and tripods originally developed for MG3 machine guns, using additional adapters.

The MG5 is available in several configurations: a standard version, a shortened and lighter infantry version (MG5 A2 with a fixed, foldable and length adjustable buttstock) and a version for installation in weapon stations. The Standard and Infantry versions which are intended for dismounted infantry feature a quadruple magnification riflescope and integrated red dot in addition to the mechanical sighting (front/rear sight), allowing for intuitive and fast targeting at short distances. The MG5 is compatible with the equipment of the German “Future Infantry Soldier-Enhanced System” and is set to become the Bundeswehr’s standard issue machine gun. The defense ministry has ordered 12,733 units, with a price tag of some 200 million euros ($222 million). 200 units had been delivered in January 2018. The rest will be delivered in coming years.

240LWS has a weight of 9.1kg. The 240LWS is made shorter than the 240LW by a redesigned telescopic stock and mounting the detachable pistol grip with the trigger and sear group further forward.

240LW and 240LWS

The combat-proven M240B machine gun has been noted for its reliability, but its weight (12.5kg) has not gone unnoticed. The infantry men want a modern machine gun that is lighter to carry and handy to operate. M240 is the U.S. military designation for the FN MAG.

Barrett Firearms, the manufacturer of firearms and ammunition, including the famous M82A1 which has been purchased by over 40 military organizations worldwide, took the initiative to make the M240B lighter and designed the 240LW taking advantage of cutting-edge modern manufacturing techniques. Barrett brought their lightweight M240LW prototype to the SHOT Show, Las Vegas in 2011. Unlike the M240L, which is in service in the Army, Barrett does not use any expensive materials like a titanium receiver and polymer trigger frame or manufacturing techniques to decrease weight. Barrett instead decreased weight by trimming off as much metal as feasible and decreased manufacturing costs by making the receiver in two pieces and then welding it together. They managed to trim about 6.2 pounds off the standard M240B. Due to some changes that Barrett has done to the existing 240 components, the life of the receiver and internal components are prolonged about 20,000 rounds longer than the standard and current FN variants. Cosmetically they will look identical, but there are some dimensional differences. In June 2014 the gun went through a process of intensive testing. Barrett took a step further with the new 240LWS. Small Arms Defense Journal, Volume 8 Number 5, November 11, 2016 (www.sadefensejournal.com/wp/?p=3758) contains a comprehensive article about Barrett 240LWS.

Compared to the 240LW, the 240LWS’ buttstock is shortened, the controls are moved forward, and it’s lighter and more maneuverable.

The 240LWS gas-operated, open-bolt, air-cooled and fully automatic machine gun has the same punch as the 240LW. The receiver is machined from forgings. The top cover has a 7-inch (17.8cm) MIL-STD 1913 optical rail, and the cover’s design makes it remain in open position, even with optics mounted. The ammunition is on M13 links and retains features that facilitate single-operator loading. The 240LWS has a quick-change fluted barrel, and the carrying handle folds in both directions for use with optics. The rear and front sights are folding types. The gas system has a 3-position adjustment. The Barrett Lightweight Handguard with accessory rail mounting points is mounted on the receiver, not on the gas tube. The folding bipod is quickly detachable. The Barrett telescoping buttstock has an adjustable length of pull and hydraulic buffer. Available colors are Black and Flat Dark Earth. Compared to the M240B, the 240LWS is 3.2kg lighter, and it should be an alternative to the more costly exotic M240L.

The M240L Machine Gun model of the M240B is 3.75 pounds (1.7kg) lighter than the M240B. It features a folding bipod, quick-change barrel assembly with integral carrying handle and gas system, feed cover, bolt assembly (which allows closing of the cover regardless of bolt position), plastic butt stock, integral optical sight rail and forward rails. The M240L MMG lightweight features are a titanium receiver, redesigned barrel assembly with re-contoured outer dimensions, titanium carrying handle, lighter weight gas housing and pistol grip/trigger frame assembly composed of a metal/polymer hybrid.

The ability to withstand high heat without any difference in shape is different between steel and titanium. If we compare the heat and cold stability of titanium versus steel, titanium is more thermally stable than steel; steel may bear around 2,700° F, whereas titanium can bear 3,300° F. The difference is 600° F (315.6°C).

The M240L’s combination with steel barrel and titanium receiver can cause trouble when the barrel is fired very hot. A quick barrel change cannot be performed then because the barrel is expanded in volume and sticks to the receiver. It has to be cooled down before it can be changed.

M60E6 can be mounted directly or adapted to all standard NATO tripods and vehicle mounts. This model with iron sights can also be ordered in the Flat Dark Earth color.

M60E6

This version is heavily upgraded compared with the famous 7.62mm M60 machine gun first used by U.S. forces during the 1950s and gradually replaced the 1919A6. M60E6 represents the latest improvements to the M60 Series of machine guns. Its predecessor, the M60E4 was developed in the 1990s for U.S. Navy SEALs. However, this initial weapon had problems and reliability issues; the later version of M60E4 made by US Ordnance solved these issues as the MK43 Mod 0. The M60E6 incorporates a number of improvements over the M60E4 and is a more reliable weapon. Like the forerunners, the air-cooled machine gun is gas-operated and belt-fed with disintegrating M13 links. It fires from an open bolt and features a quick-change barrel. Its design is light and compact which provides increased mobility and allows for accurate off-hand (shouldered) direct fire support. The top cover is made of forged 7075 aluminum with MIL-STD 1913 optical rail for mounting of optics and clip-on thermal sight. The belt pull is improved by 30 percent that provides increased reliability in harsh, dirty environments. There is an extra lock in the feeding tray that keeps the linked cartridge firm and safe, so when loading, the belt will not fall out. A receiver-mounted ammunition hanger provides a stable and secure mounting point for an ammunition pouch and isolates the feed tray from accidental damage. The ergonomic pistol grip with an improved trigger can be used with gloves. It has a push-button or ambidextrous safety. A new “captured pin” latch securely holds the trigger assembly to the receiver (in the Vietnam War, the pin could slip, and the detachable pistol grip with the trigger and sear group was lost in the jungle ground). It is light weight. The one-hand operated and light weight bipod is mounted on the receiver. The forearm/pistol grip for improved control has three M1913 rails for mounting aiming lasers and accessories. The buttstock is ergonomic with a hinged shoulder rest. It has quick detaching sling mounting points.

The M60E6 version with reversible gas piston is improved to be simple and easy to maintain. The gas regulation is self-adjusting. The front sight is adjustable, also on the spare barrel, which was not possible in the earlier versions and allows zeroing of primary and spare barrels. The offset barrel handle provides a clear sight picture and eliminates the need for a heat mitten for barrel changes. The Stellite alloy of cobalt-chromium alloys gives the barrels sustained fire capability and extended life. The hard chrome and induction hardening of the op-rod tube facilitates easier cleaning and increases the service life of the receiver. M60E6 is available with a short or a heavy fluted barrel configuration for application flexibility. The controllable rate of fire allows for accurate firing in off-hand, kneeling and prone positions. Also the weight is better distributed. Its relatively light weight and short length make it accurate when firing from the shoulder. All major components are directly interchangeable with other M60 configurations. M60E6 can be mounted directly or adapted to all standard NATO tripods and vehicle mounts.

This M60E6 is the version like the one the Danish chose with color on forearm and feed cover (pistol grip and buttstock in Flat Dark Earth. The Danish’s version is without Iron Sights as they are running optics and have Micro T-2 as their backup sight).

M60E6 for the Danish Army

The M60E6 competed for the Danish Army’s machine gun replacement program against the MG5. In 2014 the M60E6 was selected as a winner and has been adopted by the Danish Army as the M/60. The M60E6 will replace the ageing M/62 (Rheinmetall MG3) machine gun, which has been used by the Danish Army since 1962.

The Danes’ M60E6 version differs a little to satisfy their demands, which includes several modifications like taking away the irons sights and using optic only, making it lighter, more accurate and easier to fire on the move. The complete weapons package includes optics, thermal sight, lasers, rangefinders and more.

The new MG will be used as a squad support weapon. The older LMG M/62 will remain in service with second-line units and as a vehicle-mounted machine gun, where weapon weight is not important. The selected M60E6 was planned to be phased into service at the end of 2014/2015, and the estimated cost of the program was $16.6 million for 700 M60E6s with accessories. U.S. Ordnance is the only company that makes the M60E6. It’s said that versions of the M60 are in service in many countries around the world. Among its customers are Mexico, Thailand, Philippines and Honduras.

Photos by Aud Håland

Technical Characteristics

The magazine’s presentation of the cartridge is the first critical step in all auto-loading firearms’ operating cycle, and it is a key element of firing reliability. Whether the magazine is detachable or internal, it must present the cartridge at precisely the right height and angle to the bolt/slide’s forward loading stroke. This is achieved by an internal magazine spring that is attached to the magazine’s footplate (located at the magazine’s bottom end) and a follower that rides on the top of the spring, which both lifts the rounds and holds them under spring tension against the magazine’s feed lips (on the magazine’s open end) in presentation position.

When loading the magazine, the cartridges are pressed into the magazine’s open end, one on top of the other, or in tubular magazines—one behind the other, which compress the magazine spring. The follower rides on top of the compressed spring at the base of the cartridge stack. Its purpose is to power the stack upward by spring decompression during the weapon firing cycle and present each round at precisely the right height and angle to be fed into the firing chamber.

The clear majority of feed malfunctions are directly related to improper magazine-cartridge presentation. This is to say that feed malfunctions often result when the cartridge is presented either too high, too low or at the wrong angle to be properly met by the bolt/slide and carried forward into the firing chamber. There are several root causes that all involve the magazine. Here’s what to look for.

Cartridge presentation is a critical element of feed reliability. A stripped 1911 Government Model with a loaded magazine inserted in the magazine well demonstrates the proper installed height and cartridge presentation.

Root Causes of Malfunction

Load a magazine to its advertised capacity. Observe the angle at which the top round is presented. Now, carefully unload it, one round at a time. Compare the presentation of every following round for presentation consistency. Every round should look the same. If the rounds begin to change presentation angle as the magazine empties, you may well have either a follower-drag issue or a weak spring issue. Both are replaceable. However, if the round being presented appears loosely held in place by the magazine feed lips, or shifts easily beneath the feed lips as the magazine empties, the presentation problem may well be the feed lips themselves.

Feed lips wear out over thousands of rounds, and they can easily become bent by dropping your magazines on a hard surface or stepping on them. Don’t bother trying to readjust the feed lip angles by bending them back into what looks right, because it never will be—unless you happen to get lucky. Discard magazines that have damaged or worn feed lips. Don’t save them for range use—get them out of your shooting life permanently.

A magazine’s installed height is another malfunction culprit. A magazine that is installed too high will drag on the bottom of the bolt/slide. The telltale sign is obvious wear on the top edges of the magazine’s feed lips and wear marks on the bottom of the bolt/bolt carrier/slide where it passes over the magazine feed lips. What causes this condition?

Most modern magazine designs have a magazine stop in some form that visibly protrudes from the magazine’s body. In most pistol magazines, the magazine base plate acts as the stop. The stop makes positive contact with the gun’s magazine well, limiting the depth the magazine can be inserted. The purpose of the stop is to prevent over-insertion into the magazine well from a reloading palm-slap or careless grounding of the installed magazine on a hard surface.

This condition can also result from excessive wear on the gun’s magazine catch or the magazine’s catch hole that holds the magazine in place at the specified height. High capacity magazines weigh considerably more than factory-spec magazines. Loaded high capacity magazines put much more sheer stress and wear on the magazine well catch and the magazine’s catch hole. This wear is easily detectable by a loose-fitting or “sloppy” magazine. In this case the bolt’s forward stroke either misses the cartridge altogether because the cartridge presentation isn’t high enough, or it only contacts the cartridge partially, driving it downward and away from the firing chamber. Again, jam city.

In all cases, when a magazine is out of spec, replace it with a new factory magazine. Aftermarket magazines may appear to be exact clones of factory magazines, but they’re usually not unless you purchase pricier competition magazines offered by high-end manufacturers. Again—don’t keep magazines that chronically malfunction. Don’t save them for range use or give them to a less experienced shooting friend. Throw them away.

During the auto-loading feed process, cartridge travel is another critical reliability factor. Let’s imagine the cartridge traveling toward the firing chamber as it leaves the magazine. There should be no point during this travel where the cartridge isn’t either held by the magazine feed lips, or partially chambered on the bullet nose-end while being grasped on the cartridge casing’s bottom-end flange by the bolt face and/or extractor. Securing the cartridge during its travel forward from the magazine into the firing chamber is critical so that the cartridge doesn’t fall out of the gun while the bolt/slide is on its forward stroke. It also ensures feed reliability no matter what angle the gun is being held, e.g., vertically up or down, upside down, etc. Hollywood depicts weird gun holds because they look cool on screen, but there are times in extremis when one may need to reliably fire and cycle in all those positions.

This brings us to the feed ramp and its purpose. Most breech loading, magazine-fed automatic, semiautomatic and some manually operated firearms are equipped with feed ramps. Feed ramps are easily identifiable because they’re usually a tightly machined and polished metal ogive-shaped ramp located on the outside bottom of the gun’s firing chamber. The feed ramp’s sole purpose is to reliably guide the cartridge into the firing chamber as it leaves the magazine on its travel forward.

Comparing a number of different auto-loading firearms reveals there are several different feed ramp designs. For example, the AR-7’s feed ramp is part of the magazine; on the Mauser C96 it’s part of the receiver; on many pistols the feed ramp is part of the barrel. Some designs are even more subtle, like FN’s Five-SeveN pistol, which incorporates a beveled firing chamber that acts like a feed ramp.

Feed ramp geometry and cleanliness is critical to the firearm’s proper reloading cycle, making it a common point of mechanical failure. If you’ve been experiencing jams (especially when shooting one or two different shaped bullets) and you’ve already done the troubleshooting on your magazines, it’s prudent to check out the feed ramp. Here’s what to look for.

A variety of loaded magazines demonstrating different brass, steel, aluminum-cased ammunition. All have different design installed heights and presentations to the bolt/slide forward stroke.

Check Out the Feed Ramps

Feed ramps should be smooth and clean. That said, it is not uncommon to see copper deposits on the feed ramp or manufacturing milling marks. Not all manufacturers polish their feed ramps. However, if you detect an obvious rough or deformed surface, rust, pitting or the presence of attached debris (metal, carbon, grit, etc.) on the feed ramp, you can bet on the fact that the bullet nose is likely being directed off-center as it is fed forward into the firing chamber. This will almost always cause a failure to feed at some point during the forward loading stroke. The solution most shooters immediately turn to is polishing the feed ramp. While that may or may not be the solution to your failure-to-feed problem, have it done by a seasoned professional gunsmith; attempting it yourself is a bad idea, and here’s why.

Don’t Polish the Feed Ramp—Seek Professional Help

There are a number of critical, yet subtle, geometries in play when polishing a feed ramp, and changing any of them, even slightly, can cause physical damage, further exasperating the malfunction. It is important to understand that the associated tolerances involving the angles (geometry) of the gun’s frame, feed ramp and barrel throat are critical. For example, polishing the feed ramp risks rounding (radiusing) its top shoulder. Radiusing changes the shoulder angle and redirects the bullet nose off its design course of alignment into the firing chamber. The result—back in jam city. Plus, the damage you create from do-it-yourself polishing, will ultimately require an expensive professional fix.

Presentation comparison between new 1911 Wilson Combat and worn 1911 MILSPEC issue .45ACP magazines. There are about 3 degrees of difference in cartridge presentation angle between the new (foreground) and old (rear) magazines. Using the old magazine is asking for a jam.

Shape and Velocity

There are two additional variables that influence feed reliability. They are the shape of the bullet nose and the velocity of the ammunition you’re firing. As a general rule of thumb, a rounded bullet nose feeds more reliably than a pointed bullet nose, because a pointed bullet is less forgiving to feed ramp angle fluctuations and frame gaps during the feed process. Hollow points and flat-shaped bullet noses with sharp shoulders often wobble up the feed ramp, especially at higher bolt/slide velocities contributing to feed malfunctions.

Second, using ammunition that provides above-average (higher) bullet velocities means a hotter load is being used to propel it. That translates to higher bolt/slide stroke velocities (cyclic rate). When the bolt/slide cycles at higher velocities, it is more sensitive to “tight” magazines that are slower to feed. The resulting mismatch almost always leads to jam city.

If taken individually, none of the variables discussed above may cause a feed malfunction, but their cumulative effect almost always will. It is for this reason that several top professional gunsmiths offer a “Reliability Package.” As part of this package they hand-lap all frame, slide, barrel bushing, BCG, etc., and wear points for perfect fit. They polish the feed ramp to a radius that best matches the ammunition you tell them you primarily shoot. And they’ll adjust all the magazines you provide them (or purchase from them) for installed height and perfect cartridge presentation. The result is a “tuned” firearm that is as close to 100% reliable as can be mechanically attained, and it’s worth every penny if you’re betting your life on it.

Consumption

The final step in the process is consumption—firing the chambered round. Many never consider the dynamics involved when the gun goes bang and the cyclic operation that immediately follows. So let’s step through the consumption (firing) sequence and take a look at the dynamics.

Once a live round is chambered and the bolt/slide is closed and locked (in battery), the gun is ready to fire. When you pull the trigger either a hammer or a striker hits the cartridge primer. The primer fires and ignites the propellant. The propellant burns at its predetermined velocity, producing extremely hot, rapidly expanding gases as a product of propellant combustion. As the gas expands it “swells” the brass case against the firing chamber. At the same instant, it propels the bullet from its seat in the neck of the cartridge case forward onto the lands (spiral groves) running the length of the barrel’s bore. The exceptions are smoothbore shotguns and muskets, which don’t have lands.

The round has fired. As the gas continues to expand, the bullet increases velocity and spin inside the bore. The spin acts to gyro-stabilize the bullet inflight. As a bullet leaves the gun’s muzzle it becomes a ballistic projectile and subject to gravity and drag. It has achieved all the velocity it can attain. It can go no faster, and from this point on it will only slow down from effects of aerodynamic drag.

At the same moment the cartridge fires, the backstroke process begins. It’s a process because depending on the operating system’s design there may be a few milliseconds’ delay designed into the backstroke sequence. Regardless, the bolt/slide now begins its backstroke.

The backstroke accomplishes several purposes in addition to extracting the spent cartridge case from the firing chamber. As the spent cartridge fully clears the firing chamber, it contacts an ejector (usually positioned along the side of the lower receiver or lower frame). During the rearward travel, the base (primer end) of the spent cartridge contacts the ejector, and the case goes flying from the open ejection port of the gun.

The backstroke continues compressing either a recoil spring or buffer spring, which accomplishes two essential elements. Spring compression slows and stops the rear stroke, and the compressed spring stores the energy necessary to reverse the bolt/slide’s direction forward with the proper velocity to achieve the loading cycle previously discussed. At this point we have examined the complete presentation, feed and consumption cycle.

Feed ramps come in different forms depending upon the gun’s design and feed mechanism. Pictured is a stripped 1911 Government Model with barrel in place and loaded magazine installed. Note the polished feed ramp at the bottom end of the barrel. Even slightly changing the ogive geometry will cause jams.

It’s Complicated

As you may now understand, the process is a complicated sequence of mechanical steps exacted upon proper machine tolerances and regular maintenance. It is solely powered by the pressures resulting from propellant combustion, which also has a design-operating envelope. As such, there are many critical operating elements that can go wrong and cause a feed or extraction malfunction. Hopefully, you now know where to start troubleshooting.

Cartridge Cases—What Works, What Doesn’t

When fired, the cartridge case “swells” against the walls of the firing chamber. Brass cartridge cases have been used since the mid-1800s when metal-cased ammunition became the ammunition of choice and firearms were both converted and new, built to fire it. Brass is easy to form and is a relatively soft metal. Its ductility allows a swelled casing to be easily extracted from the firing chamber. It also allows easy re-sizing in the reloading process. However, brass has become increasingly expensive in modern times, driving the ammunition industry to use other materials for cartridge cases.

Following WWII, the USSR developed the ability to form steel cartridge cases. This advancement in ammunition construction is noteworthy because steel cartridges swell differently than their brass counterparts. Steel also rusts, and it isn’t nearly as ductile as brass, making extraction of a spent (swelled) round more difficult. The solution was to coat each steel cartridge case with a thin lacquer film. The lacquer serves two purposes. First, it prevents rust. Second, it liquefies under heat and pressure when the cartridge is fired and works as a lubricant to aid extraction of the expended case. Brilliant! Russia produces steel-cased ammunition today in a variety of rifle and pistol calibers. This ammunition is far less expensive than brass-cased ammunition and works as reliably in most modern rifles and pistols.

In response to DoD’s requirement to lighten the soldier’s load, the ammunition industry is also pursuing both aluminum-cased and polymer-cased cartridges. Aluminum-cased pistol ammunition is available on the civilian market with comparative performance to brass-cased ammunition of the same caliber. Polymer-cased ammunition is still being refined. Its technical maturity suffers primarily from extraction problems where casings separate upon extraction, leaving some or most of the casing lodged behind in the firing chamber. Such problems will no doubt be overcome with material design refinement, but for now, polymer-cased ammunition is not ready for combat primetime.