Bullet Form & Assemble

Advanced Projectile Manufacturing System

Servo-Driven Core Swaging At the heart of the OTM-5176FA’s integrated process, servo-driven core swaging compresses lead wire into dense, cylindrical cores with exact weight uniformity, diameter control (±0.001″), and optimal density for ballistic stability. The 75-ton servo ram enables programmable force and stroke adjustments via the Weintek HMI, incorporating bleed holes for excess material ejection and multi-program storage for quick setups. This stage ensures flawless cores ready for jacket integration, minimizing porosity and enhancing repeatability in high-volume runs.

• Process: High-pressure swaging with core seating and bleed mechanisms for precise lead formation
• Outcome: Uniform density, tight tolerances, reduced defects like core inconsistencies or voids
• Applications: Lead cores for FMJ, soft-point, and hollow-point designs across pistol to large-caliber projectiles (.380 ACP to .50 BMG)

Servo-Driven Jacket Drawing Seamlessly transitioning from core preparation, the OTM-5176FA’s jacket drawing module transforms gilding metal copper strips through blanking, cupping, and multi-stage progressive deep drawing—complete with intermediate annealing cycles for ductility. Servo controls optimize draw ratios, wall thickness uniformity (±0.001″), and elongation, preventing wrinkling, tearing, or splitting while producing seamless tubes with superior tensile strength and corrosion resistance.

• Process: Blanking discs, cupping, and deep drawing with dwell actions and lubricant management
• Outcome: Precise geometries, even grain structure, minimal waste for high-strength jackets
• Applications: Gilding metal jackets for FMJ, JHP, and TMJ bullets in military and hunting configurations

Servo-Driven Bullet Assembly Culminating the end-to-end workflow, the assembly phase unites swaged cores and drawn jackets via precise insertion and swaging, followed by ogive forming (tangent or secant profiles for low-drag aerodynamics), cannelure rolling for secure crimping, and optional tipping or boat-tailing. Programmable servo motions ensure strong bonds, aerodynamic noses, and reliable expansion characteristics, all in one pass to slash cycle times and defects.

• Process: Core-jacket unification, swaging, ogive shaping, cannelure grooving, and final profiling
• Outcome: Ballistic-optimized projectiles with uniform integrity, enhanced penetration, and controlled mushrooming
• Applications: Complete FMJ, JHP, and AP bullets for tactical, hunting, and military demands

Servo-Controlled Transfer System Powering the integrated magic, the OTM-5176FA’s advanced servo transfer system—with dual-lane options, servo bars, individual strippers, and ejectors—orchestrates flawless component flow across swaging, drawing, and assembly stations. This modular setup supports complex sequences, rapid tooling changes, and multi-feed integration, while anti-static systems and scrap chutes ensure safe, clean operations for non-stop production.

• Mechanism: Programmable servo drives for multi-station progression and alignment
• Benefit: Reduces inter-machine transfers, cuts defects, and amplifies throughput with energy-efficient motions
• Applications: Full projectile lines for FMJ assemblies, multi-piece penetrators, and specialty rounds

Integrated Manufacturing for Ammunition The OTM-5176FA redefines ammunition production by merging swaging, drawing, and assembly into a unified servo ecosystem, leveraging progressive dies and real-time feedback for unmatched precision and flexibility. This all-in-one approach minimizes material handling, optimizes energy use, and lowers total cost of ownership through reduced maintenance and downtime. Industry leaders praise such integrated systems for delivering consistent muzzle velocities, terminal ballistics, and scalability, positioning the OTM-5176FA as a game-changer for high-stakes manufacturing.

• Advantages: Seamless workflow, programmable versatility, superior repeatability, and eco-friendly operation
• Applications: End-to-end production for .380 ACP to .50 BMG, spanning military FMJ to premium hunting JHP
• Servo Benefits: Dynamic control over velocity, dwell, and force for optimized quality, speed, and safety

Robust Press Design Built as a technological fortress, the OTM-5176FA boasts an expanded weldment frame for enhanced durability, with machined bolster plates, honed rams, and heavy-duty linear guides to withstand intensive, multi-stage operations. The 75-ton capacity integrates a servo indexer for fluid cycling, while the sealed coolant tank, automatic oiler, and dedicated scrap chutes handle trim, flash, and ejects with minimal mess. Full enclosure with magnetic interlocks and 3/8″ polycarbonate guarding prioritizes operator safety, delivering a low-maintenance, high-reliability platform for relentless production.

• Components: 75-ton servo ram, integrated coolant/oiling systems, carbide tooling, advanced indexer
• Benefit: Long-term robustness with millions of cycles before service, ideal for 24/7 runs
• Environment: Clean, contained design minimizes hazards and downtime in demanding facilities