One embodiment of the present invention provides a polymeric ammunition having a metal injection molded primer insert.

One embodiment of the present invention provides a polymeric ammunition cartridge and methods of making and using the same. The cartridge includes a substantially cylindrical insert connected to a substantially cylindrical polymeric middle body. The substantially cylindrical insert includes a top surface opposite a bottom surface and a substantially cylindrical coupling element that extends from the bottom surface, a primer recess in the top surface that extends toward the bottom surface, and a flange that extends circumferentially about an outer edge of the top surface. The substantially cylindrical polymeric middle body includes a substantially cylindrical polymeric bullet-end and a substantially cylindrical polymeric coupling end connected by a powder chamber, wherein the substantially cylindrical polymeric coupling end contacts the substantially cylindrical coupling element.

One embodiment of the present invention provides a polymeric ammunition cartridge and methods of making and using the same. The cartridge includes a substantially cylindrical insert connected to a substantially cylindrical polymeric middle body. The substantially cylindrical insert includes a top surface opposite a bottom surface and a substantially cylindrical coupling element that extends from the bottom surface, a primer recess in the top surface that extends toward the bottom surface, and a flange that extends circumferentially about an outer edge of the top surface. The substantially cylindrical polymeric middle body includes a substantially cylindrical polymeric bullet-end and a substantially cylindrical polymeric coupling end connected by a powder chamber, wherein the substantially cylindrical polymeric coupling end contacts the substantially cylindrical coupling element.

A system for metal injection and counter pressure has: a particle providing assembly; and a forming unit having a melting module, a counter pressure module and a mold module; wherein, the particle providing assembly provides particles with metal powder and a binding agent to the melting module, the particles is formed into melted flow by the melting module, the melted flow is provided to the mold module, the counter pressure module provides a counter gas with predetermined pressure to the mold module, the melted flow forms into a green part inside of the mold module.

A system for metal injection and counter pressure has: a particle providing assembly; and a forming unit having a melting module, a counter pressure module and a mold module; wherein, the particle providing assembly provides particles with metal powder and a binding agent to the melting module, the particles is formed into melted flow by the melting module, the melted flow is provided to the mold module, the counter pressure module provides a counter gas with predetermined pressure to the mold module, the melted flow forms into a green part inside of the mold module.

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 at least partially over the circular recess side wall and the groove is adapted to receive polymer over the bottom surface and at least partially over the circular recess side wall.

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 at least partially over the circular recess side wall and the groove is adapted to receive polymer over the bottom surface and at least partially over the circular recess side wall.

An iron soap having a content A (%) of free fatty acid being 0.01≦A≦8.0, a content B (%) of water soluble salt being 0.01≦B≦0.5, and a granularity summary value C indicated in Formula (1) being 0.1≦C≦5.0, wherein the iron soap is a salt of a straight-chain saturated fatty acid having from 12 to 22 carbons and an iron.

Granularity summary value C=(D90−D10)/D50(where 1.0≦D50≦40.0)  Formula (1)

D10: 10% cumulative diameter (μm) of fatty acid metal salt particles on a volumetric basis

D50: 50% cumulative diameter (μm) of fatty acid metal salt particles on a volumetric basis

D90: 90% cumulative diameter (μm) of fatty acid metal salt particles on a volumetric basis

A method for manufacturing a molding mold used in an injection molding apparatus includes: generating a first plasticized material by plasticizing a first shaping material containing an amorphous metal and a resin; and shaping a laminate that is a part of the molding mold by discharging the first plasticized material toward a stage to laminate a layer.

A method for producing a bonded magnet, comprising: (i) low-shear compounding of a thermoplastic polymer and magnetic particles to form an initial homogeneous mixture thereof; (ii) feeding the initial homogeneous mixture into a plasticator comprising a low-shear single screw rotating unidirectionally toward a die orifice and housed within a heated barrel to result in heating of the initial homogeneous mixture until the thermoplastic polymer melts and forms a further homogeneous mixture, wherein said further homogeneous mixture is transported within threads of the single screw towards the die orifice and exits the die orifice as a solid pellet; (iii) conveying the solid pellet into a mold and compression molding the pellet in the mold, to form the bonded magnet, wherein the bonded magnet possesses a magnetic particle loading of at least 80 vol % and exhibits one or more magnetic properties varying by less than 5% throughout the bonded magnet.