Abstract: Two methods of making subsonic ammunition articles are provided that size the cavity to the propellant charge. The first method includes molding a core sleeve comprised of a unified neck, cavity sized to the propellant charge volume and a trailing end with an ejector ring, primer seat and flash hole; then, molding a polymer based casing over the core sleeve except the neck and a portion of the trailing end; then, inserting the primer, propellant charge and projectile; thereby, completing a subsonic ammunition article with a rigid core and a polymer casing. The second method includes injection molding a polymer sleeve within the casing of an ammunition article around a core pull positioned within the casing to form a thicker casing wall and a propellant cavity the volume of which corresponds to a desired propellant charge.

Abstract: A method of making an ammunition article and associated ammunition article is provided. The ammunition article is interchangeable with standard ammunition articles and to operate in standard chambers of standard weapons systems and of the type having a casing including a sidewall that defines a casing volume within. The method includes determining a desired propellant charge volume for a given ammunition article, determining a thickness of the casing sidewall such that the casing volume substantially corresponds to the desired propellant charge volume, and forming the casing having the determined thickness.