In May of 2010, the annual National Defense Industrial Association’s (NDIA) Small Arms Systems Symposium was rolled into a new format joining forces with NDIA’s Guns & Missiles Division to host the first ever NDIA Joint Armaments Conference. The Dallas, Texas Hyatt Hotel was packed full of Industry and Government personnel all anticipating a full schedule of academic papers and an exhibit hall loaded with new gear. Some of the hot topics this year included the growing debate surrounding 5.56mm ammunition effectiveness and new information concerning the Army’s carbine solicitation. Vendors and presenters were well rounded and included everyone and everything from the usual American suspects as well as participants from the EU, Asian Pacific Region, and even China.

Goings on in Government

A main feature of any NDIA small arms event is the plethora of interaction between government and industry personnel with this year being no different. Embodying this concept were the keynote speakers: Major General Brogan of USMC Systems Command (SYSCOM) and BG Fuller of the US Army, Program Executive Officer, PEO Soldier. The generals were not ill prepared or poorly informed as to what the crowd was there to hear and pointedly addressed some of the hottest and most contentious topics in the industry – carbine and ammunition performance – which MG Brogan referred to as a “significant and emotional event in the U.S. military.”

The USMC

MG Brogan outlined the small arms vision currently held by the USMC that includes continued fielding of the M16A4/M4/M4A1 platform with many officers now being issued M4 carbines in lieu of the traditional M9 9mm pistol as necessitated by current hostilities. He also touched on several key decisions including:

• The USMC selection of the HK416 to fulfill the Infantry Automatic Rifle requirement in Infantry Squads and LAV units as the M27 IAR.
• Selection of the Army’s M110 Semi-Automatic Sniper System (SASS) as the Marine Corps’ Long Range Precision Rifle.
• Large scale fielding of the MK 318 Mod 0, 5.56mm SOST ammunition, amongst USMC fighting units deployed in Afghanistan.

More enlightening were MG Brogan’s key questions to industry relating to both small arms and ammunition; questions that attest to the keen awareness and sensitivity such issues are viewed with. “Should we buy (in the future) an individual weapon or a family of weapons?” He further gave a suggestion that such a family could use a common platform allowing for PDW, Carbine, Combat Assault Rifle, Service Rifle, SDM, and IAR configurations. In the ammunition realm his questions were similar, “Is the current caliber effective?” Brogan continued by adding a potent caveat: “I can assure you there are many enemy combatants that can attest to the effectiveness of it.” Brogan then laid out a simple methodology should a new caliber be considered. He said, “If we are going to consider changing caliber the technology must be equal,” referring to the fact that comparisons have been made of alternate calibers (i.e. 6.8 SPC, 6.5 Grendel, etc.) to new technology 5.56mm rounds, including MK318 SOST and the Army’s M855A1. MG Brogan clearly understands that these comparisons do not accurately compare “apples to apples” so to speak and as a result any truly effective data in the raging caliber debate will only occur when all calibers are tested utilizing the same design technology (e.g. M855A1 vs. 6.8mm SPC utilizing the same bullet technology). Brogan’s formula for ammunition considerations: weight versus effect on the enemy versus ammunition expended.

Other notable information relayed during the brief included:

• Any future individual weapon contract will include provisions giving the government full ownership of the Technical Data Package (TDP) or full use rights.
• Any future weapons and ammunition must be compliant with the laws of land warfare.
• Weight savings are a must.

A presentation shortly thereafter by LTC Brinkman of USMC SYSCOM/Infantry Weapons further reinforced the points made by MG Brogan while praising current successful fieldings like the M32 Multi-Shot Grenade Launcher and the light weight infantry mortar system. On the horizon in the USMC’s future as outlined by Brinkman: more foreign weapons training kits, a long range sniper rifle, light weight machine gun, and a close quarter battle pistol (though details are lacking at this time).

The Army

As the largest service and often the traditional purchasing agent for other services, the Army also had a wealth of information in their briefing sessions. This year was no different with BG Fuller, PEO Soldier, detailing the Army’s ever changing small arms acquisition strategy. The Army’s small arms vision has completely transformed in a short period of time from “pure fleeting” M4s just two years ago to a dual path model meant to substantially upgrade the current issue M4 platform while paving the way for a full and open source carbine competition. BG Fuller expounded on details to eager industry personnel and echoed the sentiments of beleaguered Soldiers across the globe when he acknowledged, “The Soldier is not a Christmas tree that we can keep hanging items on,” bucking the trend of the past decade to keep adding kit and equipment to the basic soldier load.

The highlight topic of course was the update on the long awaited carbine solicitation. Since the past 2009 NDIA Small Arms Systems Symposium, the debate surrounding the carbine issue has not faded and events like the intense battle at COP Keating in Afghanistan, mimicking the Wanat engagement less than a year earlier, have further driven forward movement in an effort to get real time improvements into the field. The battles highlighted again the need for higher rates of fire and die hard reliability in individual weapons for U.S. troops engaged in close quarter running firefights with Taliban and other insurgent fighters. These considerations among others were significant influences leading to the dual path strategy where the Army will improve the M4 carbine while soliciting its replacement. The Army is seeking to address the M4 improvements in phases:

Phase I

* Increase the barrel mass for better performance during high rates of fire.

* Ambidextrous Safety/Selector tailoring the ergonomics to an even larger percentage of users.

Phase II

* Add an enhanced M1913 type rail adapter system to the platform. Most likely the new rail will be of the free floating type to negate operator influences on the barrel achieving a consistent point of projectile impact.

Phase III

* Explore improved operating systems to include short stroke gas piston mechanisms and a redesigned bolt carrier and bolt group with the goal of improving overall weapon reliability.

Furthermore, the introduction of the improved 5.56mm M855A1 round into service in June 2010 should mean that the “improved” carbine will be quite a potent platform, especially since M855A1is optimized for the M4 carbine and not the M16 and provides consistent terminal effects through a large variety of barriers. Fuller was cautious to add that the M4 improvement program must be managed carefully and the options well considered warning that, “we can’t spend the same amount on an improvement that we would spend to buy a new one.”

As far as the solicitation for a new replacement carbine, the going has been slow, but is advancing. As of the time of Fuller’s brief the carbine requirement was in the Joint Staff, but the industry RFP will likely be released before this article is in print. The step following is full and open competition for the Army’s new individual carbine. This competition will be historic in nature and unprecedented in recent Army history. When walking the showroom floor at this year’s event it was not at all difficult to see that this is what all of the industry’s major players are gearing up for.

Follow on presentations by LTC Henthorn at the U.S. Army Maneuver Center for Excellence (MCE- formerly the Infantry Center) and COL Douglas Tamilio, PM Soldier Weapons, were consistent with details given by Fuller. Henthorn took the time to expound more on current and soon to be fielding efforts on the Army radar:

Current Fielding Efforts

* The M110 Semi-Automatic Sniper System (SASS) is now 85% fielded to units. Some early issues with the guns have been resolved and combat surveys show acceptance and approval of the SASS by end users and commanders.

* The M320 Grenade Launcher (HK GLM) is rapidly replacing M203s among the conventional force and will soon be integrated with a day/night range finding sight.

Coming Soon to Units This Year

* The M2A1 enhanced .50 BMG machine gun with quick change barrel and fixed headspace/timing.

* The upgraded M24 Sniper Rifle chambered in .300 Winchester Magnum.

* The M240L light weight machine gun with titanium receiver, (See SAR’s 2009 NDIA Small Arms Symposium article for information on this system).

* The M855A1 improved 5.56mm round (lead free and eco friendly).

Among items Henthorn sees the Army eyeing in the future are suppressors and a sub-compact rifle.

A last note worth mentioning before closing the Army section of this article is a survey conducted in Afghanistan by PM Soldier Weapons. As briefed by the Army at his event, PM Soldier Weapons personnel spent time on the ground with units in Afghanistan evaluating how the everyday dirty boot war fighter employs his weapon system, what shortfalls could be noted, and of course what is being done well. A most interesting find is there seems to be a trend among troops to incorporate substantial amounts of aftermarket equipment into their individual weapon’s configuration, particularly the M4. It is commonplace to find non-standard stocks, grips, optics, and especially magazines integrated into the basic kit of our warfighters. This sparks an interesting and fiery debate between those who believe that troops should have the freedom to select superior commercial off-the-shelf (COTS) equipment and the official “by the book” stance of Army regulations, which requires the issuance of modified weapons orders (MWOs) and numerous tests and certifications to authorize a piece of weapon related equipment. The tone of this debate could not be clearer than the warning issued to the industry during the brief by COL Tamilio that industry suppliers who provide non-standard equipment could be encouraging Commanders and Troops to violate AR750-10, which could be detrimental to their careers.

Concern is justifiable since some sub-standard equipment was clearly being used by Soldiers who may have not been fully informed about the products they were using. It is clear, however, that troops in the field will continue to integrate innovative aftermarket solutions often contrary to the rules. The goal of the military and industry alike should be to ensure that these fighting men and women can fight with the best top quality gear without fear of reprisal. Aftermarket and non-standard pieces of equipment are often superior and it is commendable that one priority for PM Soldier Weapons is to develop a menu of authorized aftermarket items for carbines. This will be challenging to do fairly; until then, troops will continue to weigh the risks and rewards of the practice.

The Other Services

Some highlights occurring in the other armed services were also briefed as follows. U.S. Navy (CDR Tom Gajewski, USN) elaborated the Navy’s need for a .50 caliber remote weapons station to protect ships from terrorist attacks while in port. This system must possess corrosion resistant properties as expected for maritime use.

U.S. Air Force (Mr. Randy Roth, USAF Combat Arms Program) reported that the Air Force is supporting broader government efforts to include the solicitation of a new individual carbine and selection of a precision sniper rifle (PSR). Numerous equipment transitions are taking place in the service to include: replacement of the M203 40mm grenade launcher with the M320, replacement of the M2 .50 cal. with the M2A1 QCB, and transition of some M14 EBRs and M4 carbines to the MK17 and MK16 SCAR variants.

U.S. Coast Guard (Capt. Michael Price, USCG Office of Specialized Capabilities) noted that the USCG is looking into acquisition of a Precision Service Shotgun (PSS) with a rifled barrel optimized for firing slugs to disable outboard marine motors and the service is still seeking a gyro stabilized marine enhanced weapons platform to take the place of manned guns on the bows of high speed watercraft with the goal of enhancing gunner safety during operations. Due to a lack of training facilities, the Coast Guard is exploring options for effective simulators specific to the P229 DAK handgun.

Awards and Achievements

With previous coverage in SAR, there is no need to go into great detail, but it is only fitting to profile the well deserving men who received recognition at this year’s Joint Armaments Conference for their hard work and dedication in the small arms field.

Chinn Award Recipient

Mr. Frank Puzycki, U.S. Army ARDEC.
* Over 40 years in the small arms community.
* Key mover and shaker within the National Small Arms Center.
* Personally involved with seventeen ammo type classifications and 13 weapon type classifications.
* Quote: “Team work is indefensible. When Industry and Government are working together good things happen. When we’re doing this we can’t be beat.”

Hathcock Award Recipient
Mr. Jeff Hoffman, Black Hills Ammunition, founder/owner
* Began an active law enforcement career in 1979 and continues to this day.
* At 50 years of age and as head of a well established company, Hoffman is still subject to SWAT call outs.
* Black Hills Ammunition is renowned for quality in the precision marksmanship community to include MK262 Mod 0 and Mod 1 types.
* Quote: “People at the plant know to never tell Jeff ‘We can’t do that.'”

Professional Service Award Recipient
Mr. Hays Parks, DoD General Counsel
* A Vietnam veteran, having entered service with the USMC in 1963.
* Has fought numerous battles as a lawyer to prevent radical restrictions of lawful military ammunition types used by U.S. Forces.
* Has been a champion for the warfighter on the international scene facilitating the approval of new ammunition types for military use.
* Renowned debunker of misinterpretations and deliberate misrepresentations of small arms ammunition related treaties, agreements, and revisionist history.
* Quote: “The most important client I have is the Soldier, Sailor, Airman, or Marine.”

Papers and Exhibits

The NDIA Joint Armaments Conference sported a very high rate of participation from outside of the United States and a large number of vendors due to the combined nature of the Conference. With over a 100 vendors on the floor presenting products ranging from tasers to tank guns, it was largely impossible to cover every aspect in the time allotted, but for a small arms guy there were definitely some products that caught the eye including some new systems largely unseen beforehand.

Domestic

Among domestic U.S. vendors in the exhibit hall, Remington Defense was attracting a lot of attention, not only with the Gen 7 variant of the Adaptive Combat Rifle (ACR), but also with the new Remington Gas Piston Rifle (RGP). While the ACR is becoming a regular feature of these events (beginning life as Magpul’s Masada), the rifle has seen many evolutions since the base design was introduced. In the Gen 7 configuration, which eyes the military and defense markets, the polymer receiver had been replaced by an improved magnesium receiver (which I have been assured does not burn, at least not easily) and a Remington octagonal rail system. “ACR is not our original design,” Remington’s Trevor Shaw noted, “but we’ve made improvements.” On the other hand, the RGP is truly a floor up design and much more than a simple conversion of the standard AR-15 type platform. Though the ins and outs of the rifle were not fully accessible to this writer due to the system’s newness, the quality of the build was readily apparent upon inspection. The RGP features a completely monolithic upper receiver with the recognizable Remington octagonal rail design containing modular attachment points. The rifle does not have any advanced coatings as of yet, but even without it Shaw assuredly states the initial tests are very promising both in terms of accuracy and reliability. Even better to both the government and commercial consumer is the strategy behind the gun as described by Shaw, “We are looking for high reliability and quality at a good price point. We want to make the gun as affordable as possible.” Other notable features of the gun include a regulating gas system for suppressor use, ambidextrous controls, a beefed up barrel extension designed for multi-caliber applications, and upper receiver compatibility with the standard AR-15/M16/M4 lower. The RGP will certainly evolve as time passes, but the base system viewed at this event is exciting and this writer is very enthusiastic to follow the RGP’s progress. Undoubtedly Remington Defense is well postured for the Army’s upcoming carbine solicitation and M4 improvement program with strong designs in both the AR-15 and non-AR-15 configuration.

Smith and Wesson has also been hard at work under the law of supply and demand developing rifle designs geared towards the Army’s requirement. At their booth, Joe Bergeron took the time to highlight some of the company’s recent work to the AR-15/M4 system (S&W’s M&P rifle line) including the addition of fully ambidextrous controls (including the bolt release) and the integration of new “in-house” barrel technology that yields greatly extended barrel life, though due to the proprietary nature of the technology and the ongoing status of testing, no exact numbers were readily given for this article. Smith and Wesson’s rifle line includes both short stroke gas piston and direct gas impingement rifles, and of course, all uppers are compatible with the current issue M16/M4 lower receiver. Furthermore, the gas piston version of the S&W rifle allows for multiple settings for suppressor use that also includes a complete gas shut-off option. Other notable S&W developments are the introduction of Coyote Tan slides and Titanium rust resistant sights for the M&P pistol line as well as ongoing suppressor work and testing in 9mm, .40 S&W, and .45 ACP.

Heckler & Koch’s Dale Bohner was enthused to show off the company’s products. HK has seen lots of good news in the past couple of years with the selection and delivery of the M320 40mm grenade launcher to replace the Army’s aging M203s and now the recent choice by the USMC to field the HK416 as the M27 Infantry Automatic Rifle. So far, HK has delivered over 20,000 M320 grenade launchers to the Army and deliveries are continuing. The USMC’s IAR has yet to enter full rate production; according to Bohner, “We’ll deliver a quantity by November this year.” Attesting to the design quality of the original HK416, who’s legacy has become well known both due to outstanding performance and its place among the never ending carbine controversy, the M27 IAR in its final form is nothing more than an HK416 with a bayonet lug and bipod. The HK hammer forged barrel, proven in quality and longevity, coupled with the 416’s short stroke gas piston operating system is believed by many to be the combination that gave the HK system the edge needed to meet the USMC’s IAR requirement. It should be noted that the IAR will augment, not replace the USMC’s M249 SAW fleet, with the SAW being retained in most units and for vehicle use. In the meantime Bohner is optimistic, “As soon as a decision is made regarding to full rate production we can proceed.”

From the Foreign Fields

The NDIA Joint Armaments Conference was clearly global in scale this year as international issues and non-U.S. participants took the spotlight position in many of the presented academic papers and featured exhibits. Notable presenters focused on the NATO role in weapons and ammo solicitation and standardization, with some pretty contentious moments. Also worthy of comment was the presentation and exhibit of the Republic of South Korea’s new K11 Advanced Individual Weapon System (albeit with some U.S. Customs mishaps) and participation from the Chinese engineering team who provided a briefing on the 40 years of successful employment of the Type QLZ87 35mm grenade launcher and the system’s evolution in the Chinese infantry formation.

The NATO related paper topics this year focused, as with earlier papers, on the shortcomings of the 5.56mm SS109 type round being currently deployed in hostilities in Afghanistan. During his sessions, Mr. Anthony Williams of the U.K. championed the idea of evaluating a medium or optimal caliber solution that meets the needs of 5.56mm and 7.62mm users, citing difficulties with 5.56mm effectiveness at longer ranges and through intermediate barriers as experienced by British Troops serving with ISAF. Another presentation by Mr. Jim Schatz had a similar approach and made credible arguments in these budget strained times for a collaborative effort developing the next generation of individual weapons by NATO partners.

Daewoo’s K11 would have been quite a star at this show providing it had made it. Ju Hwan-Song of S&T Daewoo explained in broken English just enough to figure out that U.S. Customs had become a road block to having the actual K11 system present on the showroom floor and as a result a life sized cardboard cutout served as a space filler for the real thing. Despite this mishap, the K11 booth was intriguing and the merits of the platform and its ground breaking novelty was not diminished. The K11 is a “dual barreled weapon system” and vaguely resembles the U.S. OICW prototypes from the late 90s and turn of the century. The K11 features a 5.56mm carbine, 20mm bolt action rifle that fires 20mm airbursting smart munitions, and a sophisticated fire control system (FCS) all integrated into a single man portable individual weapon. The system is very similar in concept to the XM25 Airbursting weapon system being tested in limited field trials by the U.S. Army; the difference that Ju Hwan-Song proudly pointed out is that K11 has been fielded in mass ahead of U.S. system. The K11 replaces the ROK Army organic K201 rifle and under barrel 40mm grenade launcher; two of which are found in the typical infantry squad. The K11’s FCS allows for optical aiming of the carbine using a dual day/night IR based system that projects a digital image to the operator. The FCS also integrates a laser range finder and advanced ballistic computer that accounts for environmental effects when programming airburst ranges for the 20mm projectiles, making the K11 an effective counter-defilade weapon that is simplistic to use. As far as mechanics goes, the K11 uses modern alloys in the upper portion of the weapon with a polymer lower making it possible for the system to weigh in at a portable 6.1 kg (13.45 pounds). Ergonomically, the weapon utilizes one trigger pack and selector with the operator rotating the selector between safe, semi-auto, burst, and 20mm options with a single fluid motion. Magazine capacity for the system is five 20mm airbursting projectiles and the standard NATO type 30-round 5.56mm magazine.

At the Range

One legacy event of the NDIA Small Arms System Symposiums is the annual Firepower Demonstration where vendors get the golden opportunity to put their products into the hands of attendees and let rounds fly downrange. The Joint Armaments Conference continued the tradition with an excellent demonstration out at the Spartan Tactical range facility managed by owner Jim Smith and his staff of professional cadre. The predictions of thunderstorms and flash flooding that were rumored throughout the first two conference days, and seemed even more imminent on the day of, gave way to clear blue skies and the Texas sun. Over twenty vendors were on site showcasing everything from pistols, sniper rifles, and even truck mounted .50 cal. machine guns on three different ranges optimized for the systems being fired thereon.

At the pistol range, vendors included HK with a full suite of handguns and submachine guns, Glock, Inc. with the Gen 4 enhanced .40 caliber pistol and Ruag Ammotec with their frangible ammo line. The line was especially long for EMA Tactical where Eldad Oz (EMA’s president) and Mr. Michael Grundy could not keep the magazines loaded fast enough to satisfy the crowd waiting to fire the Roni pistol conversion kit for the Glock 17 handgun. The Roni (Hebrew for rejoice/rejoicing, but also the name of the designer, Moshe Oz’s daughter), which has seen multiple product improvements just since the SHOT Show in January, allows for the standard Glock 17 to be converted without modification into a semiautomatic shoulder fired weapon system; and when cradling a Glock 18 the Roni takes the form of a true submachine gun. The Roni delivers impressive accuracy in a small package with an integrated M1913 rail allowing for the mounting of any compatible optical devices and a sturdy sliding shoulder stock. As Grundy explained, the Roni conversion allows agencies the flexibility of fielding only a standard service pistol yet gives users the ability to achieve pistol caliber carbine/submachine gun performance. There has already been interest from across the global and domestic spectrum, with one undisclosed school system viewing the conversion as a means for better equipping school security officers to quickly respond to a Columbine type of scenario. The Roni is envisioned as a tool negating the need to secure a separate weapon on the campus premises or in a patrol cruiser, which delays response time when an incident occurs. Better yet for those who read this as a civilian, the Roni conversion kit is BATFE approved and can be mailed to your doorstep. (Introducing a pistol into the conversion, or the mere possession of the two together, can still be viewed as possessing an SBR. All NFA rules apply).

A trek past the main range and up the hill leads to Spartan’s long distance range where light machine guns, carbines, DMR rifles, and sniper systems stood ready to receive shooters. At this range vendors included La Rue Tactical, SIG, Colt Defense, HK (with the HK416 IAR variant and HK416 in 6.8mm), and Remington Defense with their new RGP rifle and Generation 7 ACR. The lines at this range gave testimony to the enthusiasm of the crowd which endured equatorial type heat to get hands on the new weapon systems. For HK, company President Wayne Webber joined Dale Bohner in assisting attendees to firing positions to fire the IAR while Remington’s Trevor Shaw stayed busy with the RGP carbine at the far right. Despite its geographical disadvantage of being located separately from the main range area by a required uphill walk through rough terrain, the long distance range was the busiest per capita at the Firepower Demonstration, likely due to the relevance of the products highlighted there.

Down at the main range facility, fifteen vendors lined the firing points, with plenty of steel and La Rue targets on the horizon. The firing line contained everything from FNH’s SCAR rifles on the far left (SOCOM has announced a decision not to field the Mk16 SCAR Light since the NDIA event), to the GUA-21 .50 cal. machine gun on towable trailer on the far right. Sandwiched in between were a plethora of vendors with a very diverse product range to include: Dr. John Kokinis of U.S. Machine Gun Armory with his semiautomatic variant of the Mk46 light machine gun, Aloysius Donovan with the Adams Arms short stroke gas piston carbine, Milkor with the M32 multi-shot 40mm grenade launcher, and LTC (Ret) Mark Westrom with ArmaLite’s AR-15 rifles. To discuss each participating company and their wares would be far too intensive for this article. To say the least, the NDIA Firepower Demo does stand as unique for small arms trade shows inside the United States with its interactive vendor demonstrations and personal one-on-one range interactions. It is commendable to NDIA that they have continuously hosted this event without incident for many years.

(A debt of gratitude is due to Mr. Sal Fanelli and Jim Schatz who, for many years running, have volunteered their time, resources, and sweat to making the Firepower Demonstration both safe and successful. Also a special thanks to LaRue Tactical, whose mobile BBQ trailer provided the large crowd with traditional Texas cuisine at the best price in town… free.)

Conclusion
With so much going on in the world, the changing winds of politics, and the inevitable cutting of defense budgets, the fact still remains that troops in the war zone need the best small arms and ammunition available. With all of these obstacles it is organizations like NDIA and events like the Joint Armaments Conference that can make the difference by consolidating the cutting edge products and the great minds that develop and employ them under one roof for three days that impact the rest of the year. From military units and government agencies that send their subject matter experts to top engineers and scientists from home and abroad, the Joint Armaments Conference is an event where business cards and email addresses are exchanged, where new ideas are birthed, and focus is honed on the path ahead for the sake of the warfighters that put their lives on the line daily in the service of their country, wherever that may be.

Metal Storm is a radically different concept for weapons and ammunition, the brainchild of a self-educated Australian inventor with brilliant intuition for practical applications in engineering, physics and electronics. Following its genesis in the early 1990s, this novel electronic ballistics technology has suffered from what might charitably be termed unrealistic expectations.

Early claims of a rate of fire capability at 1 million rounds per minute inspired some fanciful applications ranging from covert wrist guns to missile defense. Metal Storm has been a darling of the media, frequently seen on the Discovery Channel and others in highly sensationalized depictions of supergun abilities. In one particularly memorable TV episode of CSI Miami, Metal Storm-like guns were seen literally vaporizing anyone who was on the muzzle end of this terrifying weapon.

Million Rounds a Minute

James Michael O’Dwyer was 47 years old in 1991 when he sold his successful food wholesale business to devote his full energies to various inventions. Two years later, he bet the remainder of his life savings and all the money he could borrow on development of a unique weapon system that, he strongly believed, would have revolutionary applications in military and law enforcement.

Years of work in O’Dwyer’s backyard garage/laboratory ultimately yielded what would become the internationally patented Metal Storm System. A breakthrough came in 1996 when a formal study by US defense giant Lockheed Martin provided essential third-party validation for the radical concept.

Building on success of his single barrel prototype, constructed with the help of a local Australian engineer named Graham Bugden, O’Dwyer’s next breakthrough came in captivating media attention with a dramatic demonstration video. News organizations worldwide picked up the demo clip showing an incomprehensibly fast burst of 9mm rounds from a box of 36 bullet-stacked barrels that O’Dwyer had whimsically named “Bertha.” A lightning strike blast of 180 rounds stormed out in about one hundredth of a second. Yes, that’s a rate of fire better than one million rounds a minute.

Bertha showed the way to a variety of devices utilizing O’Dwyer’s clever stacked munitions principle. Prominent among these are a “smart” handgun, remotely fired munitions to replace traditional minefields, close-in protection for vehicles against ambushers and incoming rockets, plus gun pods for robotic vehicles.

But, thus far, none of these has achieved commercial success.

Game-Changing Technology

Finally, after many years of work, fueled by multimillions of dollars in developmental funding from private investors, industry partners and various military entities, the radically unconventional Metal Storm system seems on track for fielding in key roles in the Global War on Terror.

We recently talked to Metal Storm to separate the truth from the fiction and get an update on how the company has progressed from the patent office to the marketplace.

Peter Faulkner, General Manager of Metal Storm Incorporated, the U.S. licensee of Metal Storm Limited in Australia, told us, “The company has become intensely focused on product development over the past three years and the work is beginning to pay off. We are close to offering the military and law enforcement communities real products rather than ideas.”

The real products Faulkner is referring to are the MAUL, 3GL and FireStorm. Not nearly the million rounds per minute, battlefield clearing supergun once imagined by the Metal Storm inventor, but certainly more relevant to current tactical applications.

MAUL Underbarrel Shotgun

Breaching shotguns of various types are in widespread use by American forces; all relatively heavy and mechanically actuated in form and function essentially unchanged for more than a century.

The Office of Naval Research, acting on behalf of the US Marine Corps, turned to MS for a better solution. Of particular interest was the need to more efficiently launch the devilishly effective FRAG-12 fin-stabilized high explosive 12 gauge projectiles.

This was a Marine Corps Warfighting Laboratory project to see if these specialized breaching rounds could be stacked. MS delivered a bench test gun that proved successful as seen in live fire video linked on the MS website. This has led to an ONR contract to actually build a weapon for the M4 carbine, the weapon of choice for MOUT scenarios, along with lethal and non lethal rounds.

It’s now known as MAUL, a particularly appropriate acronym derived from its formal name of Multishot Accessory Underbarrel Launcher. Backed by funding of nearly a million dollars from ONR, this slim, light, electrically-fired semiauto clamp-on quickly loads with slip-in tubes pre-packed with up to five rounds of various types. MAUL is fast tracked for delivery to the Navy by June 2009 for more detailed operational evaluations.

Caliber: 18mm (12 gauge)
Ammunition: Lethal and less-lethal
Capacity: Up to 5 rounds in preloaded sleeves
Operation: Manually reloaded, electrically fired, semiautomatic
Weight Empty: 2 pounds

3GL Three Shot Grenade Launcher

The 40mm grenade launchers currently in US and allied military service that are suitable for mounting to a primary weapon such as the M4/M16 family are single shot devices. Critical seconds are lost in reloading during intense firefights.

MS offers an alternative in the light and fast-firing 3GL, a semiautomatic grenade launcher with a trio of beefy 40mm rounds stacked in a single barrel. While externally similar to recent modular grenade launchers with a pistol grip and rail mount points, the 3GL can be manually loaded by the soldier with three rounds in any combination of ammunition types, potentially from irritant cloud to high explosive.

Battery-powered electronic ignition cuts weight and complexity, allowing ultra-fast firing and improved reliability. The grenadier can immediately engage up to three targets, “walk” his rounds to a precise impact point, or put multiple rounds into a single target for maximum effect.

Caliber: 40mm
Ammunition: All common less lethal to lethal payloads
Capacity: 3 rounds
Operation: Manually loaded, electrically fired, semiautomatic
Weight Empty: 5.1 pounds
Configuration: Stand alone or attached to host weapon

The 3GL weapon and a new family of 40mm grenades that can be individually loaded by the grenadier are developing rapidly in close partnership with Singapore Technologies Kinetics (STK), known as one of the largest defense firms in Asia.

Dr. Lee Finniear, Metal Storm Limited’s CEO, confidently anticipates system safety certification so that sales demonstrations can begin soon. “We can confirm that early in the New Year (2009) we expect to qualify the 3GL and ammunition for safe man-firing….”

Multi-Barrel Versatility

Uncle Sam has fielded a wide range of remote controlled weapon mounts suitable for use on vehicles big and small for land, sea and air operations. Their common characteristic is undesirably heavy weight due to the requirement for supporting large and energetically recoiling traditional mechanical guns like the massive .50 cal. M2HB and 40mm MK19.

Metal Storm offers a compelling alternative in Redback, a 4 barrel cluster with advanced fire control and automatic target tracking as an ultra-smart remotely operated weapons system (ROWS). Produced in cooperation with STK and Electro Optical Systems (EOS), it consists of a lightweight gimbal, mount and weapon, weighing approximately 150 pounds. It includes a combat proven fire control system that has thermal and imaging sensors as well as a laser rangefinder with a 5,000 meter range.

Considerable weight is saved in mounts and the overall system because the MS concept eliminates the bulky housings and complicated mechanical apparatus needed for feeding, extraction and ejection. Additionally, a simple and effective coiled spring around each barrel and built in shock piston systems efficiently counters recoil.

Redback offers a dual role capability with significantly improved lethality and target effect, instantly attacking multiple targets with different munitions and providing a lightweight offensive and defensive capability for all vehicles or fixed assets.

And most dramatically, Redback has shown the capability to intercept rocket propelled grenades using STK’s COTS (commercial off-the-shelf) 40mm airburst munitions. It automatically tracks and registers targets, slewing at speeds up to 700 deg/sec and can acquire and fire at 3 targets in approximately 1.2 seconds, selecting the appropriate munition for each target.

A recently developed universal “tail” housing for its propellant load and primer makes nearly all existing low velocity 40mm projectiles suitable for use in Redback including high explosive, enhanced blast, air burst, and less lethal munitions. This is an important logistical consideration for economy of manufacture and ammunition commonality.

Firepower can be precisely controlled to deliver one or more munition types to target simultaneously, with the operator able to choose both fire rate and ammo to provide an intense and accurate salvo of munitions.

David Pashen, Chief Engineer and Development Manager for Metal Storm’s Australian headquarters, tells us that the work done to date on Redback has been very successful.

“We’ve undertaken tests last year to prove the effect of our rounds on an RPG warhead,” Pashen said, “showing that our system was able to place and detonate two rounds alongside a simulated incoming RPG warhead in full flight.

“The next steps for Redback,” Pashen said, “will be responding to specific customer demands for the capability and the integration of sensors leading into the full automation of the system.”

FireStorm

The four barrel weapon cluster on Redback has given rise to FireStorm, a lighter, simpler and less expensive way to discharge various types of 40mm munitions, tailorable to the tactical situation. As with Redback, electronic ignition of the stacked ammo allows variable firing rates from single shots to as high as 1,800 rpm per tube in recent testing.

FireStorm is said to have performed well in a recently-completed technology demonstration of a Mission Payload Module – Non-Lethal (MPM-NL), loaded with a selection of “less lethal” chemical and frangible ammunition newly developed by engineers at the Metal Storm US operation. Given the challenges of firing stacks of these rounds without wrecking their fragile projectile cones, this is a remarkable accomplishment unto itself.

The MPM-NL experiment in crowd control was funded by US Marine Corps Systems Command, seeking a better way to handle large scale threats without resorting to deadly force. Metal Storm officials expect to learn sometime in 2009 if contracts are to be awarded.

Battle ‘Bots

The relatively light and definitely fast-shooting FireStorm offers advantages that give it particular prominence in the fast-growing need for arming military and law enforcement robots. Metal Storm weapon modules have been successfully fired aboard Foster-Miller’s TALON and, most recently, iRobot’s Warrior.

The US Navy’s ultra high tech SPAWAR (Space and Navy Warfare Systems Command) has recently evaluated a robot-riding FireStorm system for its “Anti-Personnel Unattended Weapons Pod” on its own unmanned ground vehicle (UGV).

Arthur Schatz, who’s been with Metal Storm from the very beginning and is now VP for Business Development of the US corporation, explained that the purpose of the project was to “show the capability to have robotic systems, networked through a central command post, and patrol a given perimeter for base, area, border or facility protection.”

Schatz, a retired US Navy Commander whose professional contacts had been invaluable in obtaining initial military funding for O’Dwyer’s radical concept, told us that this latest contract culminated in a successful demonstration of the system and – when funding comes available – follow-on work is anticipated.

What’s Next?

Dr. Lee Finniear, CEO of the Australian Metal Storm Ltd, is predicting commercial success in the near future for MAUL, 3GL and FireStorm. He also sees “a number of derivatives…we plan to expand our munitions to provide the suite of lethal and less lethal munition natures that customers expect.”

Compatibility with robotic platforms is also an ongoing key focus. “The electronic lightweight nature of our technology provides substantial advantages for weaponizing small and mid-range robots,” Finniear said.

For the medium term, Finniear revealed that Metal Storm has no immediate plans to enter the arena now entirely dominated by traditional high velocity systems like the MK19 grenade machine gun. “We are finding a niche in close-in to medium range weapons and have also invested heavily in less lethal applications of our weapons.”

All in the Family

Finniear has ambitious goals for the future of the Metal Storm system, particularly in view of the collaboration agreement with STK. “Our development plan will provide the company with a family of low velocity weapons, a suite of supporting munitions, and an additional caliber in the 12 gauge MAUL weapon, he told us. “This platform really adds value to Metal Storm as a company and provides the commercial base to deliver a much wider range of capability applications.”

Postscript

Credible news reports dating from 2006 reveal a pattern of energetic attempts by China to acquire Metal Storm’s technological secrets. It is said that the Peoples Liberation Army has offered a bounty of as much as $100 million Australian dollars (about $68 million USD) for data packages. O’Dwyer himself is reported to have emphatically rebuffed an invitation accompanied by a similar sum to live and work in Beijing. There must be more to all this than just Roman Candles.

Unique Stacked Ammunition

The secret of Metal Storm is an electronically initiated, stacked projectile system that removes the mechanical elements required to fire conventional weapons. Projectiles in the barrels are lined up nose to tail and patented technology provides the ability to fire each round independent of the other. When the propellant of one round in the stack is ignited the other rounds are not affected.

Rather than using a firing pin impacting on a primer, Metal Storm weapons are electronically fired utilizing a computerized fire control system which precisely controls the ignition signal to each round in the barrel. As there is no need to mechanically reload the barrel after each round is fired, Metal Storm has complete control over the timing and rate of fire. The weapon can be used to deliver a single round or dozens of rounds instantaneously at the target.

When combined with airburst munitions, Metal Storm weapons can use precisely timed firing to create a pattern of fragmentation and blast to meet specific needs, such as to intercept an incoming RPG or missile.

Due to the light weight of Metal Storm barrels, most non-infantry configurations use multiple barrels, usually between 4 and 64. This provides increased firepower and the ability to mix munitions – to have a weapon configured to respond to different threats in different ways – such as having less than lethal or marker rounds instantly available as an alternative to the use of lethal force.

Inventor Mike O’Dwyer’s first Metal Storm rounds were essentially caseless, not unlike multiple loadings of a musket with powder topped by a patch and a cone shaped Minie Ball. These were specially contrived to take advantage of recoil forces causing “wedging and sealing” of the rounds behind. So, unlike the Roman Candle, firing the foremost one in the barrel would not normally ignite the next.

While this performed quite well, only proprietary Metal Storm loadings could be used. Practical considerations have since led to the development of a special “tail” that facilitates individually loaded cartridges for Metal Storm’s 40mm family. Now, many COTS (commercial off-the-shelf) projectiles for 40mm low-velocity weapons can be readily adapted for firing. This is particularly important to Metal Storm partner Singapore Technologies Kinetics with its extensive catalog of munitions ranging from crowd-control sponge grenades to cave-clearing thermobarics.

The new tail has undergone a great deal of development and iterative testing; producing a unit that is easy to load individually and also provides the ability to hold the rounds together during firing. Although preliminary tests have been carried out on the HEDP and practice round, the tail can be retro fitted to other munitions with little or no effort. This enables them to be fired from a 3GL launcher, either in single or stacked configurations dependant on their length.

Mindful of an oft-raised concern, we asked David Pashen, Chief Engineer and Development Manager in the company’s Australian home office, about vulnerability to accidental detonation from outside electrical sources. An emailed response from this former Major in the British Army’s Royal Mechanical and Electrical Engineers is worthy of presenting here in full:

“All Metal Storm weapon systems are designed to meet military standards for EMI (electro-magnetic interference) when used on Ground Mobile, Aircraft and Shipboard applications. As the energy levels required to initiate the charge are high, the chances of accidental detonation are extremely small. In fact to date in all tests of high levels of electronic interference it has not been possible to ignite a charge on our system. The most challenging of the use environments would be on the deck of a Navy ship or fitted to a helicopter. A high powered radar dish whilst it is operating can be problematic; however the ability to shield our technology electronically from interference in such extreme circumstances precludes any potential hazard.”

Find Out More

Metal Storm Limited has a particularly information-rich website with excellent photos and videos, plus detailed descriptions of its many products, technologies and capabilities: www.metalstorm.com

Metal Storm Limited is a multi-national defense technology company engaged in the development of electronically initiated ballistics systems using its unique “stacked round” technology. The company is headquartered in Brisbane, Australia and separately incorporated in the US, with an office in Arlington, Virginia.

Metal Storm is working with government agencies and departments, as well as industry, to develop a variety of systems utilizing its proprietary technology; an electronically initiated, stacked projectile system which removes the mechanical steps required to fire a conventional weapon. Effectively, the only parts that move are the projectiles contained within the barrels. Multiple projectiles are stacked in a barrel, each separated by a propellant load. The technology allows each projectile to be fired sequentially from the barrel.

Metal Storm’s fully loaded barrel tubes are essentially serviceable weapons, without the traditional ammunition feed or ejection system, breech opening or any other moving parts. Metal Storm barrels can be effectively grouped in multiple configurations to meet a diversity of applications.

Metal Storm technology enables a new generation of “network centric” weapons that connect with today’s battlefield. Importantly, Metal Storm enabled systems are all capable of local or remote operation through a computerized fire control system.

The elements which differentiate Metal Storm technology provide for a number of key capability advantages not available from conventional weapon technology:

• Increased lethality from conventional warheads
• Cumulative effect of firepower
• Simultaneous delivery of different munitions
• Instant selectable choice of munitions
• Variable rates of fire
• Intense bursts of repeatable firepower
• Scaled response
• Remote operation

Mr. Metal Storm

“For the first twenty minutes I thought Mike was certifiably mad.” General Wayne Downing, Former Commander of US Special Operations Command

Downing recalled this troubling observation from his initial contact with the intensely focused O’Dwyer, who was making yet another in a seemingly endless string of impassioned but ultimately futile sales presentations in Australia and America.

But that quickly changed. “After thirty minutes I realized that Mike had stumbled on probably the most revolutionary thing that could be done with firearms in about the last five hundred years,” Downing said.

The retired General, a legend in the Special Operations community, was so impressed with O’Dwyer’s radical invention that he accepted the top position at Metal Storm Limited, coming aboard in October 1999. Over the next seven years, Downing’s reputation and contacts are said to have contributed substantially to multimillion dollar government contracts for further development of the technology in various novel applications.

Midnight Brain Storms

Going Ballistic, an Australian Broadcasting Corporation television documentary from 2000, has a collection of fascinating interviews with O’Dwyer himself and key persons in his life and work.

Through it we learn that the inventor admits to being “not a particularly good student” during his high school years in a small town in Queensland, Australia. Interested primarily in the odd combination of physics at school and working on cars in his stepfather’s auto repair business, after graduation he chose to enter the workplace rather than continue on to college.

O’Dwyer’s personal and professional traits contributed to a quick rise to management level in retail and then in founding his own highly successful food wholesale company. But his compulsion for invention would not relent and the products of inspiration when he would awaken suddenly in the middle of the night began to fill a bedside sketchbook.

His son Sean recalls pages upon pages of “engines and wings and carpets and electrical points… maybe 50 ideas.” Passion for invention eventually overcame the need for comfort and security in the business world. With the blessing of his wife Rhonda, O’Dwyer sold everything in 1991 and literally took a giant step into development of his amusing concept for running shoes cooled by forced air generated from each impact on the ground.

But breezy footwear would soon give way to a dream of fantastic firepower.

Mrs. O’Dwyer recalls the genesis of Metal Storm in 1993 as yet another of her eccentric spouse’s insomniac insights. “He just woke up and he said ‘I’ve improved the gun. I’ve got to go and put this on paper,’ and he doodled for an hour or so.”

The revolutionary concept at the heart of today’s Metal Storm technology has been described by its inventor as a modification of the common fireworks Roman Candle so that its projectiles may be initiated with computerized precision.

Doodles eventually took form in a single barrel prototype and, after much ammunition experimentation, proved the practicality of sequential electronic firing of stacked caseless projectiles. With the system’s enormous military potential clearly foreseen in his fertile imagination, Mike O’Dwyer sought to convince Australia’s military establishment to bankroll further development.

“To say that I was treated as though I was a friendly kook,” the inventor recalls, “would be a polite description of the response.”

Undaunted, O’Dwyer set off to America, only to experience months of futility being rebuffed by every possible contact in the Pentagon. His luck didn’t change until after the system received a successful technical validation from a major US defense contractor.

This must have been what it took to convince Australia’s Defense Science and Technical Office (DSTO) to take a closer look, soon followed by significant funding and direct collaboration in hardware development. In addition to facilitating a distinctive trio of Metal Storm weapons from pistol to cannon caliber, the partnership gave much-needed official gravitas. Now, the “kook” inventor had the backing of serious scientists and engineers from his homeland’s defense establishment.

Blossom Point Demo

The reader is urged to access the MS website www.metalstorm.com and click the VIDEOS link. Skip the latest postings for now and reach back to July 2000, when several of the mysterious new Metal Storm weapons were live fired for key military and government representatives at the Army Research Laboratory’s Blossom Point Facility in Maryland.

This extraordinary demonstration, a joint presentation by DSTO and Metal Storm, along with new US partner Science Applications International Corporation, was attended by a number of decision makers from DARPA, the American military’s Defense Advanced Research Projects Agency. With deep pockets to bankroll cutting-edge technologies, DARPA’s backing was eagerly sought.

It’s likely that the fellow wearing a straw hat, fleetingly seen in the video, is O’Dwyer himself, cheerfully firing his VLe handgun and touching off a megafast burst from a bench test pepperbox containing six pistol caliber barrels. This produces a devastating effect on a rack of target boards and then an oddly wired tube blows 40mm holes in a junk car.

While clear tactical applications for these lethal curiosities would not gain real acceptance until several years later, it should be evident to those who view this historic video that the “certifiably mad” inventor was definitely on to something big. DARPA’s emissaries apparently agreed and, in November 2000, entered into an unprecedented developmental agreement with DSTO, together committing some $50 million dollars.

This correspondent first met O’Dwyer in May of 2001 at the prestigious NDIA Small Arms Conference, where Metal Storm had a display booth and also presented a formal technical paper to influential US and Allied defense industry personnel. Having elbowed through the crowd gathered to watch the heretofore little known firm’s dramatic video clips, we were approached by a slight and somewhat owlish fellow who introduced himself as Mike.

Turned out this was the modest but intense inventor, who proceeded to give our modest but intense magazine a personally guided tour of his visionary applications for the decidedly radical Metal Storm System. Alas, Mike had no hardware on hand to fondle and no planned participation at the annual event’s customary live fire demonstrations. So we politely listened, accepted colorful brochures and promised to stand by for further news.

Mike made sure we were on Metal Storm’s list for press releases and they began regularly arriving; product pages, as it were, for a growing catalog of delightfully intriguing weaponry.

We soon learned, for example, that techno-spooks at DARPA had awarded more than $10 million to Metal Storm for an “Advanced Sniper Rifle.” No, the end result wasn’t fielded, but that doesn’t mean the program’s resulting data package for launching innovative projectiles at hypervelocity will not find practical application elsewhere and later. It’s Metal Storm’s proprietary intellectual property that they just haven’t gotten around to yet for further development.

O’Dwyer continued to promote Metal Storm technology with missionary zeal, envisioning all manner of applications – not just military. At the heart of its civilian potential was a versatile mortar box with specialized loadings. These could be for precision fireworks displays, “sky typing” advertising messages, bombarding wildfires with suppressant chemicals, spreading pesticides and fertilizer, and mineral exploration seismology.

Nothing Personal, Just Business

While the scope of this article does not include details of the corporation’s complicated financial history, the wild ride for Metal Storm’s shareholders has been reliably reported over many years. New applications and new government experimental contracts were periodically trumpeted in press releases and news features, but no real orders for hardware were forthcoming. Investors, many of whom were regular folks of modest means, were justifiably unhappy.

Veteran insiders in the corporate structure are quick to credit O’Dwyer’s demonstrated genius and tireless promotional contributions. But, we were told in carefully crafted statements, the time came when it was necessary for “the face of Metal Storm” to step aside.

A corporate press release from February 2005 announced Director O’Dwyer’s retirement with the bland assurance that “he will continue to provide consulting advice to the company from time to time in an informal, unpaid basis.”

The inventor/founder signed over “certain existing and future intellectual property rights,” and agreed to “certain non-competition arrangements.” Then, in recognition of nearly two decades in building Metal Storm, O’Dwyer received a severance package of a half million Australian dollars (about $345,000 USD).

A gentleman to the end, James Michael O’Dwyer is quoted in the same release with a rather gracious parting shot. There is much to be learned by those who carefully read it and consider all that has been reported in this feature:

“Over the past twelve months, Metal Storm has been assembling a skilled team of qualified engineers and associated professionals to concentrate on commercialization of the technology. Now that the team is fully operational, I believe it is time to pass the baton to what is a new generation. I am confident that under the leadership of David Smith, the team can complete the next stage of the company’s development,” O’Dwyer said.

The “Program Executive Office (PEO) Soldier” is the over arching US Army organization responsible for the development, procurement, fielding and sustainment of nearly everything the soldier wears or carries. PEO Soldier at each AUSA event shows off its accomplishments in small arms, accessories and related individual and crew served weaponry within its expansive and well-staffed booth. The 2007 AUSA Annual Meeting exhibit was no exception. The PM for Soldier Weapons, Colonel Carl Lipsit, was there again and ready to discuss programs and US Army initiatives and objectives, and to provide this snapshot of ongoing efforts.

XM320 Grenade
Launcher Module (GLM)

The planned one-to-one replacement for the aging M203, the XM320 GLM, is in final testing to address numerous Army requested changes deemed advantageous before fielding. The contract for this more or less Commercial Off-The-Shelf (COTS) item was awarded to Heckler & Koch in 2005. First fielding is planned for late fiscal year 2008 and will begin with the Army’s Brigade Combat Teams (BCTs). The US Army plans to procure upwards of 60,000 M320s over the next 5 years. Final operational testing includes evaluation of the day/night sight (DNS) mounting bracket and remote activation switch. A commercial hand-held miniature laser range finder will also be procured and issued with the GLM to allow for range determination to the target, the most common reason for grenadiers missing targets with low velocity 40x46mm ordnance at ranges beyond 150 meters. The M320 will provide the war fighter with new capabilities to include modular on or off the weapon use, night fire capability and first round on target accuracy within 5 meters.

M110 SASS

The 7.62x51mm NATO Semi-Automatic Sniper System (SASS), developed for the US Army from the COTS Knight’s Armament SR-25/MK11 sniper rifle systems, has completed all testing, is in production, and by the time this article is published will have been fielded with various US Army units to include US Army National Guard units from New York. The M110 SASS brings back to the regular Army the availability of aimed and accurate .30 caliber semi-automatic rifle fire that was lost when the bolt-action US M24 Sniper Rifle fully replaced the semi-automatic Vietnam era M21. Old lessons relearned again. When you find an auto-loading sniper rifle like the M110 SASS that can deliver accuracy on par or better than a bolt-action rifle, and with that it brings the ability for rapid multiple shot/target engagement capability, a capability always appreciated in the fast moving urban combat environment, keep a place for such a “tool’ in your infantry tool box.

XM26 MASS

As has been reported in detail in a recent SAR issue, the XM26 Modular Accessory Shotgun System (MASS) has been in development for nearly 10 years. The US Army is now close to fully fielding the final weapon and has been working on various improvements to the design. This includes a new liquid (oil) hydraulic M4-style butt stock to reduce felt recoil from the relatively light weight shotgun in the stand-alone mode. 3-round and 5-round box magazines will be available for the M26 to suit the needs of both weapon mounted and stand-alone use.

M2HB QCB

PM Soldier Weapons will have released a solicitation for a Quick Change Barrel (QCB) version of the venerable M2HB heavy machine gun before this article is in print. The requirement will be for upgrades to existing guns to be installed at Anniston Army depot and then to purchase these upgrades on new guns at a later time. This requested package, available for some years from various vendors as COTS items, includes the quick-change barrel, fixed headspace and timing, new safety and an improved blank firing adapter and flash hider.

Breaking News in US Weapons Procurement: Information that Shook Up the Small Arms Community

The last several years have been “interesting” in the small arms community, as various companies jockeyed to present replacements for our legacy system; the venerable M16/M4 rifle. At this AUSA meeting, information was available that rocked the community.

Colonel Lipsit provided some insight into the then ongoing Extreme Dust Environment testing that was being conducted at Aberdeen Proving Ground in 2007. The test included the standard issue M4 Carbine (from US Army stock), the new SCAR-L Standard Carbine (prototype – LRIP design status), the HK416 Carbine (new production) and the XM8 Baseline Carbine (Spiral 3 prototypes from US Army stores). The M4 was tested with standard USGI aluminum magazines, the HK416 and SCAR-L with the vendor provided magazines and the XM8 with the polymer XM8/G36 magazine that is unique to that system. This test was intended to ascertain the performance of the US M4 Carbine in a severe dust/sand environment with various lubrication and cleaning methods/intervals applied. This is the third such test conducted on the M4 since 2006.

During the test, the weapons and test ammunition loaded in magazines and placed in magazine pouches, were “conditioned” in the dynamic dust chamber for 30 minutes. If ejection port covers were present on the weapons (M4 and HK416 only), they were closed and the bores sealed with shoot-through dust caps, SOP for soldiers in such environments. 120 rounds were then fired through each sample. The weapons were then re-exposed in the chamber again and another 120 rounds fired. At 600 round intervals the weapons were field stripped and wiped down. Lubrication was applied as per the manufacturers established guidelines for this test. At 1,200 rounds, the weapons were thoroughly cleaned. Testing continued to 6,000 rounds on each sample, the 6,000 round figure based upon the expected barrel and bolt service life as listed in the US military M4 specification document.

This testing, started in September 2007, was conducted after pressure was applied by Congress, primarily from the office of US Senator Tom Coburn, a hard charging Republican from Oklahoma and a long-time supporter of the US ground-pounder. Senator Coburn, and his equally engaged staff, orchestrated a delay in the confirmation of the then pending and now current Secretary of the Army, the Honorable Peter Geren, during the summer months of 2007. The purpose of this delay was to force the Army to evaluate the reliability of the US M4 Carbine against select op-rod 5.56mm carbines in a harsh dust/sand environment replicating as close as possible conditions in Iraq and Afghanistan. Even special fine silicon based sand of the light powdery nature found in the Arabian Gulf was obtained for this assessment. An earlier and similar test at Aberdeen in January 2007 of new M4s, M16A2s and M249s in this dust/sand environment, conducted without lubrication in hopes that reliability would increase, ended with poor results for the M4; far below what had been expected, with a stoppage occurring on average once in every six rounds fired. A second similar test conducted by the Army in May 2007 ended with an average stoppage rate of one in 88 rounds fired. This latest 2007 dust/sand test was conducted using heavy lubrication, and as a result of Congressional involvement and pressure, included three modern carbine systems each of which employs an operating rod-style gas system.

Colonel Lipsit was quick to remind this writer that there was no requirement from the User Proponent, that being the US Army Infantry Center at Fort Benning, for a replacement to the M4 at this time. Therefore this test was for data collection only for review by the US Army in its current planning for what might one day replace the current M4 Carbine when the sole source contract to Colt Defense ends in June 2009.

First Formal US Army Test of Op Rod Carbines

With the help of experts in the community, Congress mandated that in addition to testing the baseline US M4 Carbine that this assessment would also include three other systems that stand out from the ever increasing field of more than 15 commercially available op rod ARs. These three carbines were picked because they are or were recently being considered for US fielding, or are actually blooding bad guys in combat by an elite assortment of US Government organizations as is the case with the highly regarded HK416. Already fielded with select US Special Operations Forces, the HK416 Enhanced Carbine has exceeded expectations of the elite user community that have adopted it to replace M4s and MK18 CQBRs. As has been reported in the “Army Times” over the last 16 months every tier one (classified) unit within the US Special Operations Command (USSOCOM) has tested, fielded and continues to employ the HK416 today.

Even the US Army’s own relatively new and mostly unknown Asymmetric Warfare Group (AWG) selected and fielded the HK416 in 2005 but ironically has been recently told by US Army leadership that its use of the HK416, a “non-standard” carbine, creates too many questions and requests from conventional units as to why the rest of the US Army cannot benefit from the availability of superior commercial off-the-shelf op rod carbines. They were then directed to turn them in. The removal of the 416s from the AWG began in November 2007 and will likely have been completed by the time this article goes to print. AWG sources reported that even after more than 2 years of hard training and combat use, not a single part was replaced in any HK416. Because M4s are hard to come by at the moment, the AWG received FN M16 lowers (with the M16 engraving milled off and M4 over stamped) with M4 upper receivers fitted to them. The 416s were sent to the depot; their fate unclear. Superior carbines as proven by other units, paid for by the US taxpayer, cherished by highly experienced and decorated AWG unit members, removed from a highly regarded operational unit and replaced by the very weapon they elected not to field to begin with.

SCAR Lights Up the Field

The second entry within this dust test is the new SCAR (Special Operations Forces Combat Assault Rifle) being developed under contract for the USSOCOM by FNH USA, a regular and proud exhibitor at the AUSA Annual Meeting. Like the HK416, the SCAR family of rifles and carbines was developed as a result of user dissatisfaction with the documented poor performance and limitations of the 40+ year old M16/M4 platform when used hard in torturous SOF environments and on SOCOM missions. Like HK416, SCAR was developed from day one with first-hand user input and has been jointly and exhaustively tested by the expected end users, to include US Army, Navy, Marine and Air Force Special Operators in environments that closely replicate those in which the system will actually be deployed. The SCAR also uses an operating rod-style gas system and thus does away with the hollow gas tube and associated carbon fouling and heat transfer issues that have plagued the M16 and M4 with their direct gas system arrangements. It also boasts barrel life expectations of 35,000 rounds or greater and 100,000 round weapon service life, according to company and USSOCOM sources.

Dust off your XM8s

The third candidate (the word candidate may be misleading as the US Army is careful to point out this extreme dust/sand test was for data collection only. The final results will be reported to the US Army Infantry Center and be included in their ongoing Capabilities Based Assessment (CBA) intended to clarify and chart the US Army’s future path or plan for future small arms, due sometime before 2010) was the now defunct, and once US Army sweetheart, polymer based XM8. Once again operating with a piston rod, or operating rod gas system, the XM8 in its final official Spiral 3 configuration set a high water mark during reliability and environmental testing by the US Army in 2005 by achieving an impressive 18,000 round MRBEFF (Mean Rounds Between Essential Function Failure) performance rating (in layman’s terms, zero stoppages or parts failures in 18,000 rounds fired). No other official developmental carbine/rifle in the reported recent history of US Army testing has fared that well, according to sources within the test agencies.

Historical Significance

Four very different weapons in the first direct comparison test by the US Army in decades. The US M4; a combat proven and highly regarded variant of the original 1960s-era ArmaLite AR-15, first officially fielded with US forces in 1964, with its aluminum two part upper and lower receiver, add-on rail system and direct gas tube-style operating system. The HK416; a highly product improved hybrid of the famous ArmaLite platform, also sporting the two-piece forged aircraft-grade aluminum receiver design and using the proven pusher rod gas system first employed by its maker in the polymer G36 rifle in 1995, and with many of the same advantages and disadvantages of the Stoner design from which the weapon was reverse engineered. Then, the shinning star of the Tampa-based US Special Operations Command; the all business SCAR-L (L for “Light” for those versions chambered for the 5.56x45mm NATO cartridge). With its one-piece extruded aluminum upper receiver with polymer lower receiver and user exchangeable barrels, the SCAR represents a unique departure for a US military rifle in that is shares up to 82% parts commonality with its big brother SCAR-H (H for “Heavy” or caliber 7.62x51mm NATO), and the many modular variants in the SCAR family, to include the short-barreled “CQC” (Close Quarters Combat), “S” (Standard Carbine) and “SV” (Sniper Variant) models. All basically the same caliber-specific platform, but with different interchangeable parts available for the user to configure the weapon he or she needs for today’s mission. Finally, the son of G36: the XM8. Arguably the most controversial rifle since the original AR-15 was introduced into the US military in the 1960s due to the unconventional way in which it was developed by the US Army and the fierce resistance from within the US Army itself, and the small arms industry, to its possible procurement from a foreign vendor without a US production plant and one that is not part of the existing US Small Arms Industrial Base. The mere thought of the US fielding a replacement to the US M4 and M16 without full and open competition, and direct comparative testing with other available systems, doomed the XM8 from the very start. An all polymer rifle save the barrel, bolt and select internal parts with a separate upper and lower receiver arrangement, using a polymer magazine and offering the user a multitude of possible variants mostly configurable in the field, the XM8 offers some notable advancements in ergonomics, user exchangeable stock options galore and a very innovative multi-function sighting device combining all of the needed “aimers” (red dot reflex sight and IR laser aimer and illuminator), and all zeroed in one single and simple operation.

Early Results

While the US Army’s Carbine Severe Dust Tests had just been completed and the final report still being written at the time of writing, early intel indicates that all three op rod carbines finished far ahead of the M4 for reliability in this environment. Sources report that the XM8 performed best amongst this pack with one stoppage every 472 rounds. The XM8 was followed by the SCAR-L with one stoppage every 265 rounds and then HK416 with one stoppage every 257 rounds. The M4’s performance was one stoppage every 68 rounds, just barely 2 magazines fired without incident, and a reliability rate almost 7 times worse than that of the XM8 under identical test conditions and protocol, almost 4 times worse than the SCAR-L and HK416. Reliable sources within the community reported that an adjustment to the lubrication schedule for the SCAR-L was required early on in the test, that one of the ten HK416 test samples performed poorly having most of the recorded stoppages and thus lowering the overall score of the weapon system (had this one sample performed like the others it would have finished at the top of the pack) and numerous barrels were replaced on the M4s to complete the 6,000 round test. When presented with these reliability numbers the Army was quick to down play the significance of the results, stating that these tests were conducted in extreme conditions that did not address “reliability in typical operational conditions” and that “everybody in the Army has high confidence in their weapon.” However, this is not what knowledgeable users are saying to this author and SAR.

Easy Answer? Not So.

From all of this modern carbine/rifle technology to choose from, developed at a cost to the US taxpayer of reportedly $70M or more ($20M SCAR, $50M XM8, zero dollars for HK416), surely the US Army could select the best available carbine for our troops and get that to the field before the shooting is over. They could but one problem remains: there is no requirement for a new carbine, or even meaningful incremental carbine enhancements. The term incremental can be defined as the 75% or “90% solution” versus the fanciful so-called “leap ahead” or “100% solution” we in this country too often pursue while all but ignoring available and affordable incremental upgrades and enhancements offered off-the-shelf by industry. This writer is not talking about accessorizing existing platforms, such as the addition of different butt stocks, rail systems, sights and the like. We have done that with some success over the years with flat top receivers and modular rail systems. While this enhances the use of the weapon for the operator, it does nothing to address the basic function or performance of the operating system, weapon integrity, function, safety and/or operator upkeep.

While the users on the ground surely would welcome a new carbine with the enhanced capabilities now and very soon to be in use in US Special Operations units, the official procurement process starts with a properly formulated and approved Requirements Document. In the US Army this begins within the lead proponent for small arms, the US Army Infantry Center at Fort Benning, Georgia. The USAIC, as mentioned earlier, is in the throngs of their CBA to determine where they want to be in 5-10 years with US Army small arms. Shall they field a new conventional carbine in 5.56mm? Should they leverage the polymer or caseless technology being explored in the current JSSAP LSAT program? Should the new suite of US Army small arms include air-bursting, or counter defilade technology, a technology that the US Army has invested deeply in over the past years to the tune of more than $377 million for the OICW/XM25 and XM307 Advanced Crew Served Weapon programs?

Strategic Pause?

Thus, without a formal requirement for anything new, the US Army continues to procure M4 Carbines and plans to do so up until at least June 2009 when the current M4 contract expires, at the tune of up to $375 million on a sole source basis without evaluating other current COTS weapons. The US Army states clearly that the M4 meets current US Army carbine specifications; and it does. There is no argument to that point. Colt is building for the US Army the carbine they have asked for and has on multiple occasions proffered to the Army various enhancements to the weapon, most of which were not accepted as they were not required in the weapon specs. However those specifications were written more than two decades ago based on the then current performance of the M16A1/A2, long before the advent of the modern op rod AR, the unibody extruded aluminum receiver of the SCAR, or the highly modular and user configurable design of a modern weapon like the XM8.

The Smoking Gun: Soldier Perspectives on Small Arms in Combat

One has to question the wisdom of not leveraging the incremental improvements that the current modern crop of assault rifles offers the end user. This point is especially driven home when one reads the US Army sponsored, Center for Naval Analysis conducted survey of 2,600 soldiers that had returned within the previous 12 months from Afghanistan and Iraq and had engaged in a firefight using the M9, M4, M16 (A2 or A4), or M249 during their last deployment. While the majority (75%) expressed overall satisfaction with their current rifle or carbine, few had ever seen and literally none have used a SCAR-L, XM8 or the HK416 or anything of a more recent design. Their frame of reference is thus limited to only what they know and have seen first hand. Given a shorter and lighter carbine with adjustable length butt stock versus the longer, heavier M16 with fixed stock; who would not welcome that, especially when fighting from vehicles and in the urban environment? Surely then the M4 would get high marks when that question is asked; which do you like better? The real test would be to offer the soldier a look at and chance to handle the more modern COTS carbines developed in the past 10 years like those described above. Surely the results of such a survey would be far different. Why not field one or more of these proven, modern carbines in a combat unit, say to a company or battalion as we have done with the Land Warrior ensemble, and then let them tell Army leadership where to spend our precious small arms procurement dollars?

What has not been widely reported from this US Army sponsored study is that, quoting from page 17 of this report, the “Percentage of soldiers who report experiencing a stoppage while engaging the enemy” was 19% for both the M16 and M4 (26% and 30% for the M9 and M249 respectively). The report goes on to state that, “A large impact means the soldier was unable to engage the target with that weapon during a significant portion of or the entire firefight after performing immediate or remedial action to clear the stoppage” (author’s emphasis added). 18% of these same soldiers stated that they were unable to clear that stoppage and get the weapon running again during the course of that engagement with the M4, 20% with the M16, 38% with the M9 and an astonishing 41% with the M249. Nearly one fifth to almost one half of the unit was “out of the fight” due to serious malfunctions in their basic weapon. These are the statistics taken right from the US Army’s own report. When questioned, US Army officials were quick to blame poor soldier maintenance for the stoppages. Sadly, we have seen this tactic used before with early AR-15s in Vietnam and more recently with the British Marines and their SA80A2’s in Operation Iraqi Freedom; blaming the war fighter for the inherent shortcomings of the weapon system.

One can then see a direct correlation between operational reports from these 494 combat soldiers surveyed who reported poor reliability to the extent of complete failure to operate during the heat of battle and the recent poor results of the same weapons in the Extreme Sand/Dust Tests described above, results that some in the Army are saying are acceptable. It is certain that those 494 brave men and women were not so satisfied with the weapon when it was useless in their hands with the enemy all around.

One then must ask why our most elite units are not using the same standard issue rifles or carbines as used by our conventional forces and instead have sought out, tested, and have fielded with great success weapons like HK416, and soon SCAR, the USSOCOM MK46 and MK48 machine guns, the MK43, and every type of handgun imaginable except the US M9?

Not the Last Word

As reported last year by this writer, this subject is far from over. Congress is involved and is drafting new legislation to persuade the US Army to consider incremental and commercially available small arms, and ammunition enhancements, both of which can and would make a big difference on the battlefield for the solider, every solider, not just our most elite warriors. In fact, on page 29 of the CNA survey referenced above, and I quote, “Twenty-six percent of M9 users requested higher caliber ammunition and increased stopping power. M4 and M16 users echoed this recommendation. When speaking to experts and soldiers on site, many commented on the limited ability to effectively stop targets, saying that those personnel targets who were shot multiple times were still able to continue pursuit” (author’s emphasis added). Soldiers are asking for more reliable weapons and more capable, more lethal bullets and ammunition yet we continue to buy thousands more of the same small arms and millions more of the same cartridges to feed them. Is it a matter of money? Is it simply too expensive to field enhanced small arms and ammunition?

The Flawed Cost Argument

The current unit costs on the current contract for carbines, and the wealth of defense spending on programs like the Joint Strike Fighter ($4.2 billion) for R&D alone, or the Army Future Combat System (FCS) which in the current defense budget received $3.2 billion for R&D, places the modern and advantageous weapons like HK416 and SCAR, and enhanced ammunition types like improved “blind to barrier” bullets and medium caliber rifle cartridges, well within reach for all US military personnel. For the $430 million dollars spent since 1980 on so-called “leap ahead” small arms programs, from which no single weapon or new round of ammunition has been fielded, we could have fielded more than a quarter million new 5.56mm or 7.62mm SCAR rifles at $1,800 each, or 358,000 new XM8s or HK416s in the more lethal 6.8x43mm SPC caliber at around $1,200 a pop. (For comparison, the 2005 contract price for an M4 was $980, $836 in 2007). However the internal bureaucracy and strong institutional resistance to field something new in the way of a modern carbine and/or rifle, anything new that is available today not in 2010 or beyond, and has been proven by other users (and in the Army’s own tests) to be incrementally better and easily integrated into the forward deployed units, is both hugely perplexing and mind numbing to this writer and many others in the community.

The Bottom Line

There should not be a single day that any US serviceman or servicewoman steps off a truck, aircraft or ship without the very best small arms technology America can provide. That technology exists today. The funds for its purchase, fielding and sustainment are obviously available and are being spent, but on decades old technology. This issue is critically important as we lose personnel in combat every single day and any advantage, even one that is ever so minor, may improve the odds of both user survival and ultimately mission success. Our weapons should be the most reliable, hard hitting and user friendly weapons on the face of this round globe yet they are not, and we should be ashamed as a result. Our fleet of small arms is old and showing their age.

Aging Fleet of Old Warriors

The average age of our eight top “work horse” weapons from the M9 to the MK19 is 33 years, 25 years if you remove the oldest- the M2HB- 23 years without the M2HB and M203 and still 21 years old with the oldest three removed from the average. If our computers, vehicles, night fighting capability, body armor, rations or medical equipment were from the same era as that of our most recently adopted small arms (mid-1980s), our forces would be hard pressed to perform on today’s modern battlefield as they have so stunningly performed during OEF/OIF. With a few exceptions, such as the new M110 SASS or M107 sniper systems, we have not fielded any new small arms designs since the mid 1980s. Again, not just for our most elite warriors in units that we do not discuss in print, but for every Soldier, Airman, Marine, Seaman, Coastguardsman and Special Operator. Anything less is a sad compromise – a compromise that we are making today and a compromise that costs lives.

The German Success Story

Even the German military, who’s annual defense budget spending figure of EUR 29.31 billion (GDP 1.3%) is far below that of the US ($42.8 billion) and below many neighboring countries in Europe (GDP 2.0%) have since 1995 replaced nearly every one of their small arms, have added numerous new calibers and capabilities they had not possessed previously. Because of this successful incremental fielding approach, the German military has the most capable set of military small arms in the free world today. In new improved small arms they have fielded no less that six since 1995 to include handguns, rifles/carbines and sniper rifles, and are working on at least three more that this writer is aware of, a new 4.6mm handgun, lightweight 7.62mm machine gun and improved .50 caliber heavy machine gun. Nine new capabilities have been added to the German small arms arsenal also since 1995 and include the first general-issue Personal Defense Weapon within NATO, a 5.56mm LMG, .300 Win Mag and .50 BMG sniper rifles and two 40mm grenade launchers, both under barrel and 40x53mm belt-fed versions. No less than six new calibers have also been fielded within the German military in the last 10 years to include brand new high performance cartridges like the 4.6x30mm PDW round. While the Germans continue to investigate advanced technology with R&D funding, they have not forgotten their soldiers fighting on today’s battlefields and have applied the “90% solution” by fielding incrementally superior small arms and capabilities. The same can be said to a lesser degree for other NATO countries like Britain, Spain, Norway, Canada and others. Let us also not forget the substantial efforts of potential threat countries as well in their development and fielding of incrementally superior small arms.

Officially, the conventional side of the US Army has not tested a single one of these COTS German weapons for possible US adoption, not one, yet many (no less than four) are in use by select US Special Operations units over those standard US issue weapons available from US military stores and which are in fact comparable in cost or less expensive than the US equivalent.

The Consequences of Failing to Act

A highly decorated US Army Special Forces senior NCO recently stated as part of this debate, “Most of the boots on the ground in OEF/OIF will be the first to tell you that the enemy has no respect for our war fighters in a head-to-head confrontation while maneuvering with his individual weapon (M16/M4). An enemy who does not respect a Soldier’s ability to deliver pain or death will always bring the fight directly to the Soldier, at belt buckle distance.”

We would like to urge everyone to get involved in this, and help our service members to get the best weapons possible. They deserve our united support. Write your elected officials on Capitol Hill. Write the US Army and Defense Department leadership. Demand that we first test then field the best commercially available weapons and ammunition that industry offers today to all of our war fighters and that we do it now, not 5-10 years down the road.