Abstract: Molded pulp inner protective packaging for ammunition is provided. The packaging can be formed using a single molding operation without the need for drilling, punching or similar subsequent operations. Molded-in holes with sufficient precision to achieve reliable interference fit against ammunition is provided. In some cases, the single piece device includes flaps or other extensions foldable to provide support in two or more places for the ammunition. In one embodiment, precisely dimensioned rods extending from a substrate through a forming screen are used in producing molded-in holes of precise dimension.

Abstract: A deformable molded fiber product is formed by a method of felting, pressing and drying the compressed product having a uniformly spaced series of low density ridges on one surface. These ridges provide the molded fiber product with sufficient flexibility so that is may be subjected to a hot swaging like process to change its dimensions. A method of forming detents by hot pressing is also shown. The process is particularly useful in forming combustible nitrocellulose shell casings from a single pulp molding operation.