Hybrid armor - mass optimization with maximum protection

Holistic FEM-supported development of modular lightweight armor for military transport vehicles

Initial situation

A European manufacturer of tactical tracked and wheeled vehicles was faced with the challenge of developing new armor for an 18-ton class armored transport vehicle. This had to be significantly lighter than the previously used homogeneous steel armor while maintaining the same protection class in accordance with STANAG 4569 Level 3/4 - without compromising on protection or modularity. A flexible design that can be adapted to different threat scenarios was particularly important.

The challenge

The central conflict of objectives was to fulfill high protection requirements while at the same time drastically reducing mass. Further technical challenges:

• Integration of different materials (metallic, ceramic, fiber-reinforced)
• Ensuring structural integrity under high-speed ballistic loads
• Consideration of thermal effects (e.g. due to frictional heat when shooting through)
• Limitation of center of gravity shifts to maintain driving dynamics
• Modular design without compromising the protective effect

Our solution approach

In a holistic, multi-stage development process, TGM combined methods of lightweight system construction with advanced FEM simulation and systematic concept validation:

1. material selection & characterization

• High-strength lightweight materials such as AlSi matrix composite systems and technical ceramics were analyzed and validated
• Material databases have been expanded to include high-speed characteristics and temperature-dependent failure criteria

2. structure & topology optimization

• Combination of topological and topographical optimizations led to significant weight savings in support and connection elements
• Stress curves were homogenized through targeted geometry adjustments

3. system integration & mass management

• Investigation of mass distribution in the vehicle structure to avoid dynamic instabilities
• Reactive module adaptation depending on the mission loads

4. FEM-supported impact analysis

• Nonlinear FEM models with Lagrange elements and progression damage simulated splinter and hard core impacts
• Thermomechanical coupling for detecting local temperature increases during bombardment

5. holistic assessment & maturity level assurance

• Use of the TGM methodology for systematic idea generation and evaluation in the mass book
• Progress monitoring across all maturity levels (concept → prototype → pre-series)

Result

The developed hybrid armor system enables Mass saving of 28 % compared to the original steel armor - with demonstrably consistent protection after STANAG 4569 Level 4. Further advantages:

• Modular designFlexible adaptation to threat scenarios and mission profiles
• Optimized energy absorptionImproved shock distribution and reduced probability of penetration
• Increased vehicle performanceImproved maneuverability and reduced fuel consumption due to lower body weights

Conclusion

This case study shows how significant efficiency gains can be achieved through the consistent application of modern lightweight construction and simulation technologies - without compromising on protection. Modular hybrid armor represents a forward-looking building block for modern military vehicle construction.