A self-separating sabot-projectile assembly with a positive engaging attachment to eliminate rotational slippage between the sabot and projectile. The torque transmitting interface between the sabot and projectile consists of a geometric shaped depression in the rearward end surface of the projectile which mates with a matched projection of the sabot. The sabot projection is hollowed out to allow the charge pressure to aid in the engagement of the sabot and projectile.

Sabots and riders are described herein that have high torsional stiffness, providing for utility in high-speed projectiles. The sabots include multiple petals with a closed configuration comprising polymer or metal containing composites. Corresponding systems and methods also are disclosed.

From a plurality of sabots, a sabot is provided for shrouding a sub-caliber projectile to form a launch package in a gun bore for acceleration by an actuator behind the projectile. The sabot includes a forecastle, an aft bulkhead and a waist. The forecastle separates the projectile from the gun bore. The aft bulkhead abuts against the actuator. The waist connects the forecastle and the bulkhead by a radial spar that supports inner and outer flanges. The inner flange mechanically engages the projectile, and in preferred embodiments is concave. The gun bore is optimized as a pair of electromagnetic rails.

A radar-absorbing material projectile system including a projectile with an outer layer of radar-absorbing material (RAM). A carrier or armature is disposed around the projectile, protecting the layer of RAM during the firing sequence. In some embodiments the carrier is a discarding carrier which falls away after firing, rendering the projectile low-observable with regard to radar detection due to the layer of RAM.

A method of making a projectile apparatus is provided that includes making one or components of the apparatus using an additive manufacture technique such as 3-D printing or laser-aided additive manufacture. The projectile apparatus can have a projectile, a propellant, and one or more optional components such as a wading, a sabot, and an intermediary device. The projectile can be fired through a barrel having a smooth bore. Additive manufacture methods can be used that involve forming components from superalloys having nanoparticles incorporated therein. The projectile apparatus can convert gas pressure or gas velocity into a high rate of projectile spin. The projectile has long-range accuracy due to a high or sustainable velocity and high rate of spin.

A projectile apparatus is provided that includes a projectile, a propellant, and optional components such as a wading, a sabot, and an intermediary device. The projectile can be fired through a barrel having a smooth bore. A sabot is provided that can include molded features, for example, a base portion and a plurality of petal portions defining, in-part, a volume for accommodating a projectile. The sabot and wadding can include molded features that control and direct gases produced by the propellant. The apparatus can convert gas pressure or gas velocity into a high rate of projectile spin. The projectile has long-range accuracy due to a high or sustainable velocity and high rate of spin.

A sabot in which bionic structures are provided. The structures are generated or created by way of an additive manufacturing process during the manufacture of the sabot in a defined manner with respect to size, shape and/or volume and in a targeted manner with respect to the local and quantitative embedding in the sabot.

A radar-absorbing material projectile system including a projectile with an outer layer of radar-absorbing material (RAM). A carrier or armature is disposed around the projectile, protecting the layer of RAM during the firing sequence. In some embodiments the carrier is a discarding carrier which falls away after firing, rendering the projectile low-observable with regard to radar detection due to the layer of RAM.

A cartridge casing having an open neck at one axial end and a closed rear portion at the other axial end to form an interior cavity for propellant. A projectile within the open neck to seal the cavity so the bullet is released when the propellant is primed and ignited. The projectile has a proximate end releasably secured within the neck of the casing facing the cavity and exposed to the forces generated by ignited propellant. The remote end of the projectile is formed by a lead core while the proximate end has a transverse surface and is at least partially formed of an amorphous metallic alloy having properties of bulk metallic glass (BMG). Liquid metal alloy can also be used at the interface of a propellant chamber in a bore of a cannon and a cartridge-free projectile.

A sabot petal is described herein comprising a plurality of woven axial and undulated fibers angled to transfer setback loads. In some cases, the petal is a one-piece component configured to be positioned around a long rod projectile or other aerostructures or aeroshell shapes to be launched with in a gun bore, or rocket or missile launch tube. Corresponding systems and methods are also disclosed.