Based on the models
already on the market, we have manufactured
six types of nonlethal projectiles. We have made convex heads out
of polyurethane foam (PUR) filled with mineral fillers like alumina
(Al2O3) and montmorillonite (MMT). We chose
a suitable holder for nonlethal projectiles. Also, we made a custom
industrial model and used CAD modeling in SolidWorks to simulate the
deformation of the nonlethal projectiles. The polymeric nonlethal
projectile holders were then 3D-printed. We performed a dynamic mechanical
analysis (DMA) and discussed the results. Likewise, we conducted ballistic
impact experiments on nonlethal projectiles (XM1006) and nonlethal
projectiles manufactured that were evaluated using a rigid wall and
a pneumatic launcher. Furthermore, we looked at cell structure, the
spread of the mean pore diameter, and the particle size distributions
of the mineral fillers using scanning electron microscopy (SEM). We
evaluated and discussed injury risks from nonlethal impacts. Data
on nonlethal projectile lethality and safe impact speed are collected.
This study explains how lab studies and real-world practice coexist
through nonlethal projectile properties.