Aspects of the disclosure are directed to manufacturing an insert-molded expanding projectile. Aspects of the disclosure include locating a portion of a projectile body within a converging tip mold, the projectile body including a metal jacket extending from a tail portion to a nose portion and surrounding an interior solid core. The metal jacket and nose portion may be tapered in a forward direction to an annular forward edge defining an opening to an undercut interior cavity. Melted polymer may be injected into the converging tip mold and allowed to cool thereby forming a polymer tip having a main portion forward of the opening and a tip retention portion filling the undercut interior cavity and having a shape corresponding to the undercut interior cavity to retain the polymer tip in place.

Aspects of the disclosure are directed to manufacturing an insert-molded expanding projectile. Aspects of the disclosure include locating a portion of a projectile body within a converging tip mold, the projectile body including a metal jacket extending from a tail portion to a nose portion and surrounding an interior solid core. The metal jacket and nose portion may be tapered in a forward direction to an annular forward edge defining an opening to an undercut interior cavity. Melted polymer may be injected into the converging tip mold and allowed to cool thereby forming a polymer tip having a main portion forward of the opening and a tip retention portion filling the undercut interior cavity and having a shape corresponding to the undercut interior cavity to retain the polymer tip in place.

A bullet (100), having: a main body (102) with a bore (106) bounded by a sidewall (124); an insert (104) that is disposed in the bore and that has longitudinal splines (460) configured to form a longitudinal flute (4620 in the insert and to provide radial support for the sidewall of the bore. A leading end (466) of the flute is open.

A bullet having a front unit and a rear unit, the front unit adapted to house the rear unit is provided. The front unit has a fragmented section, a cavity wall section, and a separation ring. The separation ring being angled forward or rearward with respect to the center of the bullet or with respect to the outermost edge of the bullet and being disposed on the front unit between the fragmented section and the cavity wall section.

Modular cartridges are disclosed that can be initially assembled, disassembled, and reprocessed by hand. The cartridge case is suitable for use with a variety of projectile designs and weights and for use with a range of propellant amounts and primer types. The variety of projectiles and range of propelling forces permits the present invention to provide cartridges for all types of uses, including indoor and outdoor target shooting, training, non-lethal self-protection, and lethal uses. The cartridges include a case, a projectile, a primer, and a selectable amount of propellant (if any), and primer housing insert” and which is configured to be releasably attached to the striking end of the case and to contain the primer and the desired amount of propellant.

Modular cartridges are disclosed that can be initially assembled, disassembled, and reprocessed by hand. The cartridge case is suitable for use with a variety of projectile designs and weights and for use with a range of propellant amounts and primer types. The variety of projectiles and range of propelling forces permits the present invention to provide cartridges for all types of uses, including indoor and outdoor target shooting, training, non-lethal self-protection, and lethal uses. The cartridges include a case, a projectile, a primer, and a selectable amount of propellant (if any), and primer housing insert” and which is configured to be releasably attached to the striking end of the case and to contain the primer and the desired amount of propellant.

Modular cartridges are disclosed that can be initially assembled, disassembled, and reprocessed by hand. The cartridge case is suitable for use with a variety of projectile designs and weights and for use with a range of propellant amounts and primer types. The variety of projectiles and range of propelling forces permits the present invention to provide cartridges for all types of uses, including indoor and outdoor target shooting, training, non-lethal self-protection, and lethal uses. The cartridges include a case, a projectile, a primer, and a selectable amount of propellant (if any), and primer housing insert” and which is configured to be releasably attached to the striking end of the case and to contain the primer and the desired amount of propellant.

Modular cartridges are disclosed that can be initially assembled, disassembled, and reprocessed by hand. The cartridge case is suitable for use with a variety of projectile designs and weights and for use with a range of propellant amounts and primer types. The variety of projectiles and range of propelling forces permits the present invention to provide cartridges for all types of uses, including indoor and outdoor target shooting, training, non-lethal self-protection, and lethal uses. The cartridges include a case, a projectile, a primer, and a selectable amount of propellant (if any), and primer housing insert” and which is configured to be releasably attached to the striking end of the case and to contain the primer and the desired amount of propellant.

Frangible firearm projectiles, firearm cartridges containing the same, and methods for forming the same. The firearm projectiles are formed from compacted metal powders that may include an anti-sparking agent. The compacted metal powders may be or include a compacted mixture of metal powders that may include powders of one or more of iron, zinc, bismuth, copper, tungsten, nickel, boron, and/or alloys thereof, and/or oxides thereof. The compacted mixture may be heat treated for a time sufficient to form a plurality of discrete alloy domains within the compacted mixture. The frangible firearm projectile may be formed by a mechanism that includes vapor-phase diffusion bonding and oxidation of the metal powders and that does not include forming a liquid phase of any of the metal powders or utilizing a polymeric binder. The anti-sparking agent may include a borate, such as boric acid.

A rifled barrel has a cylindrical channel longitudinally extending within the rifled barrel between an oppositely oriented muzzle opening and a breach opening, the cylindrical channel having a rifled portion and a non-rifled portion, the rifled portion having a land and a groove helically extending along a surface of the cylindrical channel from the muzzle opening toward the breach opening, the non-rifled portion being smooth and having a consistent diameter along a length. The diameter of the non-rifled portion of the cylindrical channel is equal to a diameter of the rifled portion measured between oppositely oriented sections of the groove. A transitional section of the rifled portion has a diameter measured between oppositely oriented land sections that gradually decreases along a section of the rifled portion adjacent to the non-rifled portion until equaling the diameter of the non-rifled portion.