Sustaining legacy fleets, like the UH-60 Black Hawk, provides a unique opportunity to incorporate novel materials. In addition to improving system performance and reducing weight, modernization efforts must consider configurational flexibility and simplicity to support operations across diverse scenarios.
One example includes how soldiers are protected from ballistic threats when operating UH-60 helicopters. Current ballistic protection systems use bulky overlays that interface with both the helicopter’s floor and other hardware, dramatically increasing weight and decreasing cabin volume. To address this, the Army funded a Small Business Innovation Research (SBIR) contract. CPS was awarded the contract to design a novel armored floor that provides ballistic protection and which can be implemented in both legacy (UH-60) and future vertical lift (FVL) rotorcraft.
The CPS Solution
To meet the Army’s requirements, CPS developed a modular solution that eliminates complex overlay systems, integrating ballistic protection into the flooring itself. The bottom layer of the floor uses our HybridTech Armor® for ballistic protection, combined with a thin layer of ultra-high-molecular-weight polyethylene. The ballistic protection layers are contained within an aluminum/honeycomb structure, enabling integration with the helicopter’s internal structure. The HybridTech® layer is independently installed and may be removed in non-combat scenarios. The final product is a lightweight, reconfigurable floor for use in any rotorcraft, with added ballistic protection designed to surpass current systems while lowering overall mass.
CPS HybridTech Armor®
CPS HybridTech Armor® offers a wide range of benefits that make it the perfect solution for UH-60 flooring.
These benefits include:
- Ballistic protection – Armor that effectively withstands a wide range of ballistic threats, including those outlined by the U.S. Army.
- Weight reduction – The SBIR effort placed emphasis on the development of lightweight flooring. The Army was looking for weight savings to support maneuverability and extend mission duration.
- Interoperability – Armor that allows greater integration of functionalities, such as seat tracks for medically-focused flight operations.
- Cost-efficiency – Armor systems that balance the cost of materials with lifecycle cost savings.
- Maintenance and durability – Armor systems that balance protection and resistance with wear and tear, allowing for extended missions and the ability to maintain in the field.
- Size –HybridTech Armor®’s thinner profile allows the Army to maintain cabin volume in the UH-60 without sacrificing protection.
Testing UH-60 Floor Systems
CPS puts our products through an intense testing process to ensure we are providing our customers the final product that satisfies their demanding technical requirements.
Ballistic Test
To test the effectiveness of our armor, and the flooring overall, we fired multiple rounds of 0.308 caliber armor piercing bullets at a roughly one-half-inch plate of our layered solution.
During this test, complete penetration only occurred by shots with a velocity far exceeding the requirements outlined by the U.S. Army.
Drop Test
In addition to testing the ballistic performance of the solution, it was important to confirm that the product design met the mechanical requirements and durability standards of the Army. One of these tests is the “box drop test,” which involves dropping the corner of a wooden box at various parts of the plate to ensure it will not be damaged during regular use.
Global Innovation at CPS Technologies
Ready to discuss your MMC design needs?
CPS offers a suite of innovative solutions to give clients complete peace of mind in their solution. With our state-of-the-art AlSiC composite, proprietary machining processes, and time-tested expertise, we’ll show you why CPS is a trusted partner in the industry.
Choose CPS for Advanced Military Metal Matrix Composite Solutions
While lightweight armor has predominantly been a government and defense technology, it offers a plethora of commercial applications. With the increase in the commercial aerospace, armored vehicles, and drone markets, lightweight armor solutions are no longer strictly a military technology.
CPS Technologies’ HybridTech Armor® offers a compelling solution. The in-the-field combination of lightweight design, superior protection, thermal management capabilities, durability, and more continue to push the boundaries of modern armor applications.
That’s why industry-leading partners continue to choose CPS for their armor solutions.
Want to learn more about how CPS Technologies and our HybridTech Armor® can enhance your operational capabilities? Contact our material specialists today!
