Near-Net-Shaping Methods for Ceramic Elements of (Body) Armor Systemsl

Shape-forming techniques which may be useful in producing components for body armor are reviewed. The techniques are classified in three general categories, dry, wet, and plastic. The different shaping techniques are compared based on key parameters including shape limitations, rate of production, cost, and safety. The techniques are evaluated as to their suitability to be used to produce different body armor components such as breast plates, deltoid, shin and knee protection, and helmets. Dry-pressing is the current standard for producing relatively flat components such as breast plates, but performance is limited by the inherent problem associated with dry-pressing, namely, the difficulty in producing homogeneous green bodies because of agglomerates in the powder. Plastic processing has the potential to be useful to produce more reliable flat components with improved performance due to high shear mixing breaking up agglomerates. Wet (colloidal) processing techniques such as gelcasting and freeze casting may be useful to produce components with high curvature and more complex shape such as helmets. Tiles or segments may be combined to produce shaped components with increased flexibility.