The present invention provides a primer insert for use in a polymeric ammunition cartridge includes a top surface opposite a bottom surface and a extraction flange that extends circumferentially about an outer edge of the top surface; a coupling element that extends from the bottom surface, wherein the substantially cylindrical coupling element is adapted to receive a polymer overmolding; a primer recess in the top surface that extends toward the bottom surface, wherein the primer recess comprises a recess bottom and a circular recess side wall; a primer flash aperture through the recess bottom that extends through the bottom surface, wherein the primer flash aperture is adapted to receive a polymer overmolding to form a flash hole; and a groove in the primer recess positioned around the primer flash aperture adapted to receive a polymer overmolding, wherein the groove extends at least partially over the bottom surface and the groove is adapted to receive polymer at least partially over the bottom surface.

The present invention provides a method of making a substantially cylindrical insert by metal injection molding by providing a primer insert injection mold to form a substantially cylindrical metal primer insert, injection molding the metal injection molding feedstock into the primer insert injection mold to form a first substantially cylindrical metal primer insert having a first size; debinding the first substantially cylindrical metal primer insert to remove the first binding agent; and sintering the first substantially cylindrical metal primer insert to remove the second binding agent and form the substantially cylindrical metal primer insert having a second size.

The present invention provides a polymer ammunition cartridge having a primer insert having: a top surface; a bottom surface opposite the top surface; a coupling element that extends from the bottom surface, wherein the coupling element comprises an interior surface and an exterior surface, wherein the interior surface comprises: a transition region that transitions from the bottom surface to a second segment wherein the transition region has a radius of from 0.1 to 0.2; a first segment extending from the second segment and terminates at a tip, wherein the first segment has a first segment distance from 0.06 to 0.14 inches and the second segment has a second segment distance from 0.05 to 0.15 inches, wherein the second segment has a second segment angle from +3 to −3 degrees relative to the first segment angle and the first segment has a first segment angle from +6 to −6 degrees from perpendicular to the top surface; a primer recess in the top surface that extends toward the bottom surface; a primer flash aperture positioned in the primer recess through the bottom surface; and a flash aperture groove in the primer recess and positioned around the primer flash aperture and adapted to receive a polymer overmolding through the primer flash aperture.

The present invention provides a polymer ammunition cartridge having a primer insert having: a top surface; a bottom surface opposite the top surface; a coupling element that extends from the bottom surface, wherein the coupling element comprises an interior surface and an exterior surface, wherein the interior surface comprises: a transition region that transitions from the bottom surface to a second segment wherein the transition region has a radius of from 0.1 to 0.2; a first segment extending from the second segment and terminates at a tip, wherein the first segment has a first segment distance from 0.06 to 0.14 inches and the second segment has a second segment distance from 0.05 to 0.15 inches, wherein the second segment has a second segment angle from +3 to −3 degrees relative to the first segment angle and the first segment has a first segment angle from +6 to −6 degrees from perpendicular to the top surface; a primer recess in the top surface that extends toward the bottom surface; a primer flash aperture positioned in the primer recess through the bottom surface; and a flash aperture groove in the primer recess and positioned around the primer flash aperture and adapted to receive a polymer overmolding through the primer flash aperture.

One embodiment of the present invention provides a method of making a polymeric ammunition cartridge having wicking texturing about the projectile aperture.

One embodiment of the present invention provides a method of making a polymeric ammunition cartridge having wicking texturing about the projectile aperture.

A fully automated, integrated, end-to-end synchronized and compact manufacturing system produces polymer or metal case ammunition. Manufacturing stations support case assembly, sealing (gluing/welding), final product inspection, cartridge packaging or binning, and loading. Station modularity facilitates rapid changeover to accommodate ammunition of differing calibers. Sensors and apparatus may be provided to place a manufacturing cell in a wait state until all components or materials are received in a preferred orientation for proper assembly. The system may join and use multipart cases, each including a lower portion with a head end attached thereto and at least one upper portion having a necked-down transition to the open top end. Elevator feeders, vibratory bowl feeders, and robotic pick-and-place feeders may be used to deliver components for assembly.

A fully automated, integrated, end-to-end synchronized and compact manufacturing system produces polymer or metal case ammunition. Manufacturing stations support case assembly, sealing (gluing/welding), final product inspection, cartridge packaging or binning, and loading. Station modularity facilitates rapid changeover to accommodate ammunition of differing calibers. Sensors and apparatus may be provided to place a manufacturing cell in a wait state until all components or materials are received in a preferred orientation for proper assembly. The system may join and use multipart cases, each including a lower portion with a head end attached thereto and at least one upper portion having a necked-down transition to the open top end. Elevator feeders, vibratory bowl feeders, and robotic pick-and-place feeders may be used to deliver components for assembly.

One embodiment of the present invention provides a stamped metal primer insert for a polymeric ammunition cartridge comprising: a top surface having a stamped flange that extends circumferentially about an outer edge of the top surface; a stamped coupling element that extends from the flange to a coupling tip; a stamped inner coupling element from the coupling tip to a bottom surface, wherein the bottom surface is opposite the top surface; a stamped primer recess in the top surface that extends toward the bottom surface; a primer flash aperture in the primer recess through the bottom surface; and a groove stamped in the primer recess around the primer flash aperture adapted to receive a polymer overmolding.

The present invention provides an injection molded primer insert for polymer ammunition comprising: a top surface opposite a bottom surface; a primer flash hole aperture positioned in the top surface extending through to the bottom surface; a substantially cylindrical coupling element extending away from the bottom surface forming an interior surface inside the substantially cylindrical coupling element and an exterior surface; a primer recess in the top surface that extends toward the bottom surface, a primer flash aperture positioned in the primer recess to extend through the bottom surface, and a flange that extends circumferentially about an outer edge of the top surface, wherein the flange is adapted to receive a polymer overmolding.