US Army reveals 3D printed grenade launcher called RAMBO

RAMBO could revolutionize war: US Army reveals 3D printed grenade launcher that can be made on the battlefield

Researchers built a 3D printed grenade launcher that consists of 50 parts

Used additive manufacturing process for a majority of the parts

However, the trigger and firing pin were printed in 4340 alloy steel

The barrel and receiver were printed from aluminum, which took about 70 hours

3D printed grenades were printed using molten zinc that was poured into a mold

Published: 13:28 EST, 10 March 2017 | Updated: 14:19 EST, 10 March 2017

The US army envisions a future where they can 3D print their weapons on the battlefield.

Researchers have unveiled a 3D printed M203 grenade launcher, which successfully launched printed grenades during live-fire tests.

Called RAMBO, the weapon is a modified M203 grenade launcher that consist of 50 components - all of which were printed expect for the springs and fasteners.

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The US army envisions a future where they can 3D print their weapons. Researchers have unveiled a 3D printed M203 grenade launcher, which successfully launched printed grenades during live-fire tests

HOW WAS IT MADE?

RAMBO consists of 50 components -and only the springs and fasteners were not printed.

A majority of the modified M203 grenade launcher was developed using additive manufacturing process, which is a type of 3D printing that layers materials as it prints to create a 3D object.

However, the trigger and firing pin were printed in 4340 alloy steel and the barrel and receiver from aluminum.

A M781 40 training round was chosen as the design for the 3D printed grenades.

Because the traditional training rounds are made using zinc case, which can not be printed, the team had to find another method.

After a few trial and errors, researcher decided to use a wax printer to make the mold for the grenade bodies, which they could pour molten zinc into a plaster mold.

RAMBO, which stands for Rapid Additively Manufactured Ballistics Ordances, was a collaboration between the U.S. Army Armament Research, Development and Engineering Center (ARDEC).

Not only does the process costs 'tens of thousands of dollars less' than traditional methods, but it will let researches build and test prototypes in a matter of days rather than months.

The team conducted a live-fire test in October, which they deemed a success.

Following 15 rounds, the printed weapon showed no signs of degradation and the demonstration went as planned - there was no wear on the barrel and the launcher held together.

A majority of RAMBO was created using the additive manufacturing process, which is a type of 3D printing that layers materials as it prints to create a 3D object.

'RAMBO is a tangible testament to the utility and maturation of additive manufacturing,' researchers shared in a blog post.

'It epitomizes a new era of rapidly developed, testable prototypes that will accelerate the rate at which researchers' advancements are incorporated into fieldable weapons that further enable our warfighters.'

'Additive manufacturing (AM) is an enabling technology that builds successive layers of materials to create a three-dimensional object.'

Some of RAMBO's main components were fashioned with harder, more sturdier materials.

The trigger and firing pin were printed in 4340 alloy steel and the barrel and receiver from aluminum.

A majority of RAMBO was created using the additive manufacturing process, which is a type of 3D printing that layers materials as it prints to create a 3D object

The barrel and receiver were made a direct metal laser sintering (DMLS) process, which heats up the particles of powder below their melting point.

Both of the parts took about 70 hours to print and then another five hours of post-process machining.

The barrel was tumbled in a abrasive rock bath, which gave it a shine and then underwent a Type III hard-coat anodizing.

Anodizing creates an extremely hard, abrasion-resistant outer layer on the exposed surface of the aluminum.

RAMBO is a modified M203 grenade launcher that consist of 50 components - all of which were printed expect for the springs and fasteners.

The barrel and receiver (pictured) were made a direct metal laser sintering (DMLS) process, which heats up the particles of powder below their melting point. Both of the parts took about 70 hours to print and then another five hours of post-process machining

And the total cost of the powered metals was about $100 a pound.

'This may sound like a lot of time and expensive material costs, but given that the machine prints unmanned and there is no scrap material, the time and cost savings that can be gained through AM are staggering,' the researches explained.

'The tooling and set-up needed to make such intricate parts through conventional methods would take months and tens of thousands of dollars, and would require a machinist who has the esoteric machining expertise to manufacture things like the rifling on the barrel.'

Because the traditional training rounds are made using zinc case, which cannot be printed, the team had to find another method. Researchers decided to use a wax printer (pictured) to make the mold for the grenade bodies, which they could pour molten zinc into a plaster mold

A M781 40 training round was chosen as the design because the researcher felt it was simply and did not involve any energetics, such as explosives and propellants – which are still awaiting approval for use in 3D printing. Pictured is the printed grenade

Once the grenade launcher was finished, the team moved on to the ammunition – 3D printed grenades.

And it consists of just four main components: the windshield, the projectile body, the cartridge case and a .38-caliber cartridge case, which was the only part not printed.

Because the traditional training rounds are made using zinc case, which cannot be printed, the team had to find another method.

THE TERRIFYING REALITY OF 3D PRINTED GUNS

In May 2013, the world's first gun made with a 3D printer was unveiled.

At the time it sparked major controversy – some derided it as nothing more than a toy, others warned it was a serious security risk that was undetectable by metal detectors.

One year on, the chilling reality of 3D-printed guns has been revealed as enthusiasts across the world show off their 'toys'.

A multitude of videos on YouTube show just how 3D-printed guns began to show up over the past few years The first was unveiled by Cody Wilson, a 25-year-old law student at the University of Texas.

His primitive design was the Liberator – but that proof of concept has been vastly improved since May 2013.

3D-printing gun enthusiasts now gather at a website called Fosscad (Free Open Source Software & Computer Aided Designs).

Here, users share their designs for 3D-printed guns, which can be downloaded by anyone. Japanese Zig Zag 3D printed revolver was first to fire six bullets.

These M781 components were 3D-printed during a six-month collaborative effort. They cost tens of thousands of dollars less than identical components created with standard production methods

After a few trial and errors, the researchers decided to use a wax printer to make the mold for the grenade bodies, which they could pour molten zinc into a plaster mold.

The team explained that by successfully creating a one-off testable prototype such as RAMBO will 'radically accelerate the speed and efficacy with which modifications and fixes are delivered to the warfighter'.

And researchers would have the ability to create different variations of design in a single printing build in a matter of hours or days – no more waiting months for a finished prototype.