CaskDefence's Special Design Unit (SDU) is dedicated to conceptualizing, engineering, and delivering highly customized bullet-proof, blast-resistant, and shrapnel-proof panels and integrated protective systems. We address unique operational challenges and specific threat profiles for vehicular, structural, maritime, and aerial applications, ensuring enhanced survivability and mission success. Our solutions leverage advanced materials, including our proprietary Woven Kevlar® fabric, and cutting-edge manufacturing techniques.
Consult with Our SDU Experts
The CaskDefence Special Design Unit (SDU) operates at the intersection of advanced material science, precision engineering, and tactical understanding. We collaborate closely with clients—military forces, law enforcement agencies, and security organizations—to analyze specific threats, operational environments (e.g., urban warfare, maritime interdiction, high-altitude operations), and platform constraints. This enables us to develop bespoke protective solutions that offer optimal performance, weight efficiency, and seamless integration.
Our SDU's capabilities span the full lifecycle of custom armor development: from initial concept and threat vulnerability assessment, through advanced CAD/CAE modeling and simulation (including finite element analysis for blast and ballistic impact), material selection (utilizing CaskDefence Woven Kevlar® fabric, advanced ceramics, composites, and metallic alloys), rapid prototyping, rigorous ballistic and environmental testing (to STANAG 4569, NIJ, MIL-STD-810G), to final manufacturing and integration support. We excel in creating add-on armor kits, integrated structural protection, and specialized components for land, air, and sea platforms.
Explore SDU ApplicationsThe SDU's expertise is applied across a wide range of defense and security challenges, providing innovative solutions where standard products may not suffice. Our focus is on delivering survivability enhancements tailored to the precise needs of the end-user and the specific operational environment.
Design and integration of modular add-on armor kits (appliqué) and integrated ballistic protection for a wide range of tactical wheeled vehicles, armored personnel carriers (APCs), infantry fighting vehicles (IFVs), main battle tanks (MBTs), and specialized logistics vehicles. Protection solutions address threats from small arms fire, IEDs, EFPs, RPGs, and artillery fragments, compliant with STANAG 4569 Levels 1-5 (and higher for specific requirements). Includes spall liners, underbelly blast protection, transparent armor, and specialized protection for critical components (engine, fuel tanks, crew compartment). Lightweight composite solutions using CaskDefence Woven Kevlar® fabric are prioritized to maintain vehicle mobility and payload capacity in diverse terrains, from desert sands to mountainous regions.
Development of ballistic and blast-resistant panels, walls, doors, windows, and modular protective structures for critical infrastructure (e.g., command centers, power plants, communication hubs), forward operating bases (FOBs), checkpoints, embassies, and safe rooms. Solutions are engineered to withstand specific threat levels (e.g., small arms, mortar fire, VBIEDs) and can be integrated into new constructions or retrofitted onto existing buildings. Performance examples include panels capable of defeating multiple 7.62mm AP rounds or mitigating blast effects from significant explosive charges at specified stand-off distances.
Lightweight armor solutions for naval vessels, patrol boats, rigid-hulled inflatable boats (RIBs), and special operations craft. Protection focuses on critical areas such as the bridge, engine room, weapon stations, and crew-served weapon positions against threats like small arms fire, machine gun rounds, and shrapnel. Materials are selected for corrosion resistance and performance in harsh maritime environments (salt spray, humidity, UV exposure). Solutions are designed to minimize impact on vessel speed, maneuverability, and stability.
Development of ultra-lightweight ballistic protection for fixed-wing aircraft and helicopters. Applications include cockpit armor, crew seat protection, floor armor against ground fire, and shielding for critical flight systems and fuel tanks. Focus on minimizing weight penalty while providing essential protection against small arms, anti-aircraft artillery fragments, and MANPADS shrapnel. Advanced composite materials, including specialized CaskDefence Woven Kevlar® fabric layups, are key.
Beyond standard helmets and vests, the SDU designs bespoke PPE for unique roles or threats. This includes specialized EOD suits with enhanced blast and fragmentation protection, custom-fitted ballistic shields for entry teams, anti-riot gear with specific impact and penetration resistance, and covert armor solutions for dignitary protection details. Human factors and integration with existing equipment are critical design considerations for these specialized PPE items.
The SDU assists clients in upgrading existing platforms or systems by integrating advanced armor materials or redesigning protective components to meet new threat assessments or performance requirements. This can involve replacing older armor with lighter, more effective solutions, or developing new mounting systems for better integration and maintainability. This service leverages our deep knowledge of material properties and structural engineering to enhance the survivability of legacy systems.
CaskDefence SDU employs a structured yet flexible methodology to ensure the development of optimal bespoke protective solutions, emphasizing client collaboration at every stage.
Intensive consultation with the client to fully understand operational needs, specific threat environments (e.g., kinetic energy projectiles, blast overpressure, fragmentation patterns), platform constraints (weight, space, power), integration requirements, and desired protection levels (e.g., STANAG, NIJ). This phase is critical for defining the precise scope and performance targets for the custom solution.
Development of initial design concepts using advanced CAD tools. Selection of appropriate ballistic materials (e.g., CaskDefence Woven Kevlar® fabric, ceramics, composites, alloys) based on threat analysis, weight targets, and cost considerations. Iterative design reviews with the client to refine concepts and ensure alignment with operational needs.
Utilizing Finite Element Analysis (FEA) and other CAE tools to simulate ballistic impacts, blast effects, and structural responses. This virtual testing optimizes armor design, predicts performance, and reduces the need for extensive physical prototyping, saving time and resources. Engineering for manufacturability and ease of integration is also key at this stage.
Fabrication of prototypes based on finalized designs. Comprehensive testing of prototypes, including live-fire ballistic trials at certified ranges (against specified ammunition/fragments), blast testing, and environmental durability tests (MIL-STD-810G). Test results are meticulously documented and used to validate or refine the design. Client witnessing of tests is often encouraged.
Production of the final armor solution under strict ISO 9001:2015 quality management systems. This includes rigorous inspection of raw materials, in-process quality checks, and final product verification to ensure adherence to all specifications and performance standards. Full traceability of materials and manufacturing processes is maintained.
Providing expert support for the integration of the custom armor solution onto the client's platform or into their infrastructure. Offering tailored training programs for operation, maintenance, and field repair (if applicable). CaskDefence SDU also provides through-life support, including spare parts, repair services, and consultation for future upgrades or modifications.
When standard solutions fall short, trust the CaskDefence Special Design Unit to engineer and deliver bespoke protective systems that meet your most demanding operational requirements. Our commitment to innovation, quality, and client collaboration ensures you receive the optimal armor solution for enhanced survivability and mission success. Contact us to discuss your unique challenges.
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