Abstract: Methods and systems are provided for firearm muzzle brakes. In one example, a muzzle brake comprises: a body; a projectile entrance and a projectile exit; a gas-actuated valve biased toward the projectile entrance within an interior of the body; and a projectile opening of the gas-actuated valve arranged along a projectile path between the projectile entrance and the projectile exit.

Abstract: An improved polymer-based cartridge includes a primer insert defining a base end and connected to a cartridge body that extends forward to a shoulder region and has a length defined by industry standards for that caliber. A cartridge nose extends forward from the cartridge body and has an industry standard outer angle. An interference region, noncompliant with the industry standards, connects the industry standard angle to the neck. The interference region causes interference between the cartridge nose and a shoulder support surface defined by an industry compliant firearm chamber of the same caliber. The improved polymer cartridge thus exceeds maximum dimensions set by industry standards. A second interference region can be defined at the distal end of neck and is a result of an increase to the overall axial length of the cartridge in comparison to the corresponding length in an industry standard cartridge.

Abstract: The invention herein describes an aerodynamically improved projectile which has less overall mass and achieves higher maximum velocities. The projectile has a jacket with a nose opening and a base opening and a core disposed therein. The core is open-ended and has a channel defined from the open forward end to the open base end. The channel is axially aligned with the nose opening and base opening of the jacket. Removably attached to the base opening is a base cover that is engineered to detach from the projectile during flight. A pressure differential created in the channel during projectile flight causes the base cover to detach from the projectile, thereby fully opening the channel.

Abstract: A keyed projectile for use in conventional or conventionally modified weapons systems is disclosed. The projectile core has one or more recessed portions defined in an outer surface. The core is covered with the projectile jacket that locks into the recessed portions to form the keyed projectile. The recessed portions, or keys, can be circumferential grooves, axial grooves, circular grooves, through-holes or any combination thereof. The keyed projectile has an increased resistance to disintegration caused by rotational separation mid-flight due to extremely high levels of RPMs during flight. A method for forming the keyed jacketed projectile is also disclosed.

Abstract: A method is disclosed for coating a projectile for use in an ammunition cartridge. A polymer jacket is applied to an undersized projectile core of a first standard caliber to bring the outer dimensions of the jacketed projectile into compliance with those of a second, larger caliber projectile. The polymer jacket coating may produce a non-uniform outer diameter of the polymer jacketed projectile and may include a plurality of circular cavities defined therein. The polymer-jacketed projectile may be a bullet for pistol or rifle ammunition, or a pellet, or shot for use in a shotgun shell.

Abstract: Methods and systems are provided for firearm muzzle brakes. In one example, a muzzle brake comprises: a body; a projectile entrance and a projectile exit; a gas-actuated valve biased toward the projectile entrance within an interior of the body; and a projectile opening of the gas-actuated valve arranged along a projectile path between the projectile entrance and the projectile exit.

Abstract: Methods and systems are provided for firearm sound suppressors including a gas deflector. In one example, a suppressor comprises a housing, a projectile entrance, a projectile exit, one or more baffles, and a deflector chamber. The deflector extending outward from the housing and the deflector curving around a central axis of the suppressor.

Abstract: A method is disclosed for coating a projectile for use in an ammunition cartridge. A polymer jacket is applied to an undersized projectile core of a first standard caliber to bring the outer dimensions of the jacketed projectile into compliance with those of a second, larger caliber projectile. The polymer jacket coating may produce a non-uniform outer diameter of the polymer jacketed projectile and may include a plurality of circular cavities defined therein. The polymer-jacketed projectile may be a bullet for pistol or rifle ammunition, or a pellet, or shot for use in a shotgun shell.

Abstract: The present invention provides a two piece and a three piece primer insert for ammunition piece. Each of the individual pieces may be formed by punching, pressing, stamping, molding, milling, coining, or by additive manufacturing. The individual pieces may be joined by clinching, pressing welding soldering, sintering, adhesive gluing, staking, and iterative addition by forming one piece into another piece.

Abstract: A projectile for use in a firearm ammunition cartridge, and a method of forming the projectile the projectile including a core, a jacket in which the core is disposed, the jacket having a closed rearward end and an open forward end, the forward end tapering inwardly toward a longitudinal centerline of the jacket to define an ogive portion of the projectile, and extending past a forward end of the core to form an open space inside the jacket between the forward end of the core and the forward end of the jacket, and a plurality of ventilation ports formed proximate the forward end of the jacket, each of the ventilation ports having a first opening on an inner surface of the jacket defining the open space, and a second opening on an outer surface of the jacket.

Abstract: A powder compaction device is disclosed. The device has a drive motor operable connected to a compaction rod that moves through a loading platform to a cartridge holding platform. A powder loading station is positioned below the loading platform and above the cartridge holding platform. The compaction rod moves through the powder loading station, which loads a predetermined volume of propellant powder into one or more reliefs defined in the compaction rod. The cartridge holding platform has a removable cartridge fixture designed to receive an ammunition cartridge to be loaded and compacted with propellant powder. The propellant powder is released into the cartridge fixture from the reliefs as the compaction rod passes a funnel defined at an upper end of the fixture. After releasing the powder, the compaction rod continues into an interior chamber of the fixture to compact the powder contained therein.

Abstract: The present invention provides three piece primer insert for use in polymer ammunition comprising: an upper primer insert portion comprising an upper primer insert bottom portion, a substantially cylindrical coupling element extending away from the upper primer insert bottom portion; and an upper flash aperture that extends through the upper primer insert bottom portion, a lower primer insert portion in contact with the upper primer insert portion, wherein the lower primer insert portion comprises a lower primer insert top portion positioned adjacent to the upper primer insert bottom portion at a connection joint, a lower flash aperture positioned in the lower primer insert top portion and aligned with the upper flash aperture, and a primer recess that extends away from the lower primer insert top portion to an extraction flange and in communication with the lower flash aperture; and a connecting portion that secures the upper primer insert portion and the lower primer insert portion wherein the connecting po

Abstract: The present invention provides a diffuser ring adapted to fit a primer recess in an ammunition cartridge comprising: a diffuser ring sized to fit in a primer recess for an ammunition cartridge comprising a diffuser top surface opposite a diffuser bottom surface, a diffuser aperture positioned through the diffuser top surface and the diffuser bottom surface such that the diffuser aperture can align with a flash hole, a diffuser neck positioned about the diffuser aperture to extend away from the diffuser top surface, wherein the diffuser neck is sized to fit at least partially through the flash hole, and a ring connected to the diffuser neck, wherein the ring comprises a ring aperture connected to the diffuser neck to align the ring aperture and the diffuser aperture.

Abstract: The present invention provides a diffuser cup adapted to fit a primer recess in an ammunition cartridge comprising: a diffuser ring sized to fit in a primer recess for an ammunition cartridge comprising a diffuser top surface opposite a diffuser bottom surface, a diffuser aperture positioned through the diffuser top surface and the diffuser bottom surface such that the diffuser aperture can align with a flash hole, a diffuser neck positioned about the diffuser aperture to extend away from the diffuser top surface, wherein the diffuser neck is sized to fit at least partially through the flash hole; a ring connected to the diffuser neck, wherein the ring comprises a ring aperture connected to the diffuser neck to align the ring aperture and the diffuser aperture; and a cup wall attached to the diffuser ring to extend away from the diffuser bottom surface, wherein the cup wall is configured to frictionally fit a primer and frictionally fit a primer recess.

Abstract: A method of forming a projectile for use in a firearm ammunition cartridge, the method including mixing a first material and a second material having different densities to produce a core mixture, disposing the core mixture in a die, heating the core mixture to the melting point, removing the core mixture from the die, quenching the core mixture, and plating the core mixture with a jacket material.

Abstract: The present invention provides a method of making a metal injection molded ammunition cartridge comprising the steps of: providing an ammunition cartridge mold comprising a bottom portion having a primer recess extending into the bottom portion adapted to receive a primer, a flash hole positioned in the primer recess through the bottom surface; side walls extending from the bottom portion to a nose end aperture, wherein a propellant chamber is formed between the nose end aperture and the bottom surface; injecting a metal composition into the ammunition cartridge mold to form a metal injection molded ammunition cartridge; and removing the metal injection molded ammunition cartridge from the ammunition cartridge mold.

Abstract: The present invention provides a primer insert for a polymer ammunition cartridge. The primer insert has a top surface opposite a bottom surface. The top surface has a primer recess defined therein, which is in fluid communication with the propellant chamber of the ammunition cartridge through a flash hole defined through the bottom surface. A groove is defined in the primer recess and surrounds the flash hole. A planar portion of the bottom surface surrounding the flash hole is connected to a vertical coupling element by a transition region. The transition region has a first and second concave portions positioned around a transition protrusion. An extraction flange is formed about the top surface.

Abstract: The present invention provides polymer ammunition, ammunition cartridge, ammunition case, and portions thereof having traditional and non-traditional cartridge shapes or profiles.

Abstract: The present invention provides a method of making a metal injection molded ammunition cartridge comprising the steps of: providing an ammunition cartridge mold comprising a bottom portion having a primer recess extending into the bottom portion adapted to receive a primer, a flash hole positioned in the primer recess through the bottom surface; side walls extending from the bottom portion to a nose end aperture, wherein a propellant chamber is formed between the nose end aperture and the bottom surface; injecting a metal composition into the ammunition cartridge mold to form a metal injection molded ammunition cartridge; and removing the metal injection molded ammunition cartridge from the ammunition cartridge mold.

Abstract: The present invention provides a two piece and a three piece primer insert for ammunition piece. Each of the individual pieces may be formed by punching, pressing, stamping, molding, milling, coining, or by additive manufacturing. The individual pieces may be joined by clinching, pressing welding soldering, sintering, adhesive gluing, staking, and iterative addition by forming one piece into another piece.