Integris Composites Advancing Ballistic Protection Production.

7th June 2024

Integris Composites is at the forefront of innovation in ballistic protection production, leveraging cutting-edge 3D measurement technology to ensure precision and reliability. By integrating advanced 3D measuring arms and detailed programming, the company achieves exceptional accuracy in producing ballistic panels, visors and optics-protection that are tailored to specific customer requirements.

The use of a 3D measuring arm allows Integris Composites to perform precise measurements for new records, ensuring that all points and dimensions are accurately placed. This technology is crucial for verifying that all manufactured panels meet the stringent tolerances specified by customers.

"The 3D measuring technology ensures that every panel is produced to exact specifications, eliminating any guesswork and enhancing overall quality," says Tjalfe Nørregaard Schmidt, Quality Manager.

3D ballistic scanning

The production process at Integris begins with the creation of a DXF file for the cutting machine, followed by the panel's production and measurement. The 3D measurement arm is then used to confirm that all cut-outs and outer dimensions are accurate. This meticulous process ensures that each panel meets the specified requirements before approval and reporting.

"Our rigorous process includes detailed measurements and reporting to guarantee that every panel fits precisely where it needs to, ensuring the highest level of protection and reliability,” explains Stefan Viernes Olsen, Quality Assistant.

Integris Composites' commitment to quality extends beyond individual panels. They utilize general tolerances and standards widely accepted in industries such as windmill and automotive manufacturing. This standardized approach provides a reliable framework for measuring and verifying the dimensions and tolerances of ballistic protection panels, ensuring consistency and accuracy across all products.

Enhancing Solutions with 3D Technology

Sven Døfler Poulsen, Senior Design & Application Engineer at Integris, emphasizes the importance of 3D technology in their operations.

-“The integration of 3D scanning capabilities enables Integris to deliver better-fitted solutions for various platforms, including older military assets that lack precise drawings. This technology allows for comprehensive scans and adjustments to account for any tolerances that may be out of scope.”

For instance, many military vehicles are over 20 years old, making it challenging to obtain accurate specifications. In such cases, Integris uses 3D scanning to create precise drawings used as templates for ballistic protection. This ensures that even without original blueprints, Integris can develop and fit protective solutions accurately.

3D ballistic scanning

Adapting to Shipbuilding Variability

There are significant differences in precision between aircraft and ships. While aircrafts are built with high precision, ships often have variations measured in centimeters. Variability necessitates the use of 3D scanning to accommodate these differences which is also for new ships built. This adaptability is crucial in ensuring that the ballistic panels fit perfectly regardless of the ship's build variations.

Early Involvement and Consultancy Approach

Integris is shifting towards an approach where they act as consultants early in the design process, rather than waiting until the last minute. This proactive involvement allows them to optimize the design and provide better solutions from the start. Their goal is to engage in proper engineering consultancy early on, helping to develop optimal solutions for vehicles and ships. This method is not only more efficient but also cost-effective, ensuring the best possible outcomes for their clients. By reducing the overall weight of a vehicle and achieving better protection levels or improved weapon systems, Integris provides the best scenarios for their customers.

By optimizing the design of the ballistic solution, Integris enables the customer to:

- increase the survivability (protection level)
- enhance mobility (performance - reduced weight)
- increase offensive/defensive capabilities (weapon systems - firepower)
- develop countermeasure systems or other equipment.