Abstract: There is provided a mold apparatus and process whereby a warhead body can be fabricated in a single over molding process which may also include therein metal fragments, metal balls, obturators, boat tails and other aerodynamic features, metal rings and/or threads. Other molds and processes are presented whereby a warhead body may be over molded in a polymer matrix in sequential steps which may include adding therein metal balls, then fragments, and any of obturators, boat tails and other aerodynamic features, metal rings and/or threads, as desired. Still another process for fabricating a warhead body is presented whereby an insert section is first preloaded with metal fragments and covered with a skin, then the insert section is inserted into an oversized area in a mold, and polymer is then loaded around the insert section to form a unitary warhead body.

Abstract: A munition is rendered less sensitive to inadvertent initiations by providing a polymer liner on the entire inside surface of the munition. A thermoplastic liner may be fabricated totally within an empty inert munition casing by spraying a layer of electrostatically charged low melt thermoplastic material particles over substantially the entire inside surfaces of the munition casing, which casing is first electrically grounded. After thickening the particle layer through heat, further such layers may be then applied there over, until a desired cumulative thickness liner is fabricated.