Fabrication of Lightweight Armored Doors for HMMWVs
A document describes a concept for fabricating lightweight armored doors for the Army’s high-mobility multipurpose wheeled vehicles (HMMWVs). Essentially, the concept is to reinforce high-hard (HH) steel armored doors used on some HMMWVs with a laminated, woven, high-tensile-strength glassfiber/ polyester-matrix composite that has performed well as armor material in previous military applications. A fabrication procedure for implementing the concept, described in the document, can be summarized as follows:
- Prepregs (sheets of the woven glass fibers pre-impregnated with the uncured polyester resin) are cut to sizes and shapes to fit their assigned place in the door.
- Cut prepregs are stacked as multiple plies to obtain the required thickness.
- Using the HH steel door panel as a mandrel or mold, the prepreg stack is vacuum-bagged and cured into the final composite form by heating according to a prescribed temperature- versus-time schedule.
- The HH steel door panel and the composite panel are prepared for adhesive bonding, then assembled with a polysulfide adhesive, then vacuum-bagged for room-temperature or optional elevatedtemperature curing of the adhesive.
- Other steps (e.g., installation of weatherstripping) in the ordinary fabrication of the door are completed.
This work was done by James P. Wolbert and David M. Spagnuolo of the Army Research Laboratory. For more information, download the Technical Support Package (free white paper) at www.defensetechbriefs.com/tsp under the Manufacturing & Prototyping category. ARL-0016
This Brief includes a Technical Support Package (TSP).

Fabrication of Lightweight Armored Doors for HMMWVs
(reference ARL-0016) is currently available for download from the TSP library.
Don't have an account?
Overview
The document titled "Lightweight HMMWV Armored Doors: A Detailed Approach of the Fabrication Process" by James P. Wolbert and David M. Spagnuolo, published in February 2007, serves as a comprehensive reference guide for the fabrication of lightweight armored doors specifically designed for the High Mobility Multipurpose Wheeled Vehicle (HMMWV). The report is intended to provide insights into the processes and methodologies involved in creating hybrid armor panels, which are crucial for enhancing the protection and operational capabilities of military vehicles.
The report outlines the intent to detail the fabrication process, emphasizing that it is more of a reference guide than a standard operating procedure. It highlights the importance of lightweight materials in armor design, which can significantly improve vehicle performance without compromising safety. The authors discuss various materials and techniques used in the construction of armored doors, focusing on the balance between weight, strength, and ballistic protection.
Additionally, the document mentions that some work has been conducted on HMMWV body panels, indicating ongoing research and development in this area. This suggests that the findings and methodologies presented in the report may be part of a broader effort to enhance the overall armor systems of military vehicles.
The report is structured to provide clear and concise information, making it accessible to military personnel, engineers, and researchers involved in vehicle armor development. It includes technical details that can aid in the understanding of the fabrication process, as well as considerations for future improvements in armor technology.
Overall, the document contributes to the field of military vehicle protection by offering a detailed examination of the fabrication of lightweight armored doors, which are essential for modern combat scenarios. It underscores the significance of innovation in materials and design to meet the evolving demands of military operations. The findings are not to be construed as an official Department of the Army position unless specified by other authorized documents, and the report is approved for public release, ensuring that the information can be disseminated widely for educational and practical applications.
Top Stories
INSIDERLighting Technology
Using Ultrabright X-Rays to Test Materials for Ultrafast Aircraft
INSIDERManufacturing & Prototyping
New 3D-Printable Nanocomposite Prevents Overheating in Military Electronics
INSIDERDefense
F-22 Pilot Controls Drone With Tablet
Technology ReportAR/AI
Talking SDVs and Zonal Architecture with TE Connectivity
INSIDERManufacturing & Prototyping
New Defense Department Program Seeks 300,000 Drones From Industry by 2027
INSIDERAerospace
Anduril Completes First Semi-Autonomous Flight of CCA Prototype
Webcasts
Test & Measurement
SAE Automotive Engineering Podcast: Additive Manufacturing
Information Technology
A New Approach to Manufacturing Machine Connectivity for the Air Force
Automotive
Optimizing Production Processes with the Virtual Twin
Power
EV and Battery Thermal Management Strategies
Manufacturing & Prototyping
How Packet Digital Is Scaling Domestic Drone Battery Manufacturing
Automotive
Advancements in Zinc Die Casting Technology & Alloys for Next-Generation...



