Metal Storm

"Metalstorm" redirects here. For other uses, see Metal Storm (disambiguation).

Metal Storm Limited (ASX : MST) is a research and development company that specializes in electronically initiated superposed load weapons technology. Metal Storm is both the name of the company and the technology.

Metal Storm Limited

Company type	Public (ASX: MST)
Industry	Defense
Founded	1994
Headquarters	Brisbane, Australia
Key people	Terence James O'Dwyer, Chairman
Website	http://www.metalstorm.com

The company is based in Brisbane, Australia with a subsidiary in Arlington, Virginia, U.S.A. Metal Storm owns the proprietary rights to the electronic ballistics technology invented by J. Mike O'Dwyer. The company has over 30 worldwide patents covering aspects of ballistics technology.

Technology

The concept of stacked projectiles (multiple projectiles loaded nose to tail in a single gun barrel with propellant packed between them) predates Metal Storm. The roman candle, a traditional firework design, employs the same basic concept; however, the propellant for the leading projectile continues to burn in the roman candle's barrel, igniting the charge behind the subsequent projectile. The process is repeated by each charge in turn, ensuring that all projectiles in the barrel are discharged sequentially (and inevitably) from the single ignition. Various methods of separately firing each propellant package behind stacked projectiles have been proposed which would allow a 'single shot' capability more suitable to firearms.

J. Mike O'Dwyer, an Australian inventor, observed that these methods did not eliminate the problem of unintended propellant ignition caused by hot gases 'leaking' back up the barrel. Mike O'Dwyer's original Metal Storm patents demonstrated a method whereby projectiles placed in series along the length of a barrel could be fired sequentially and selectively without the danger associated with unintended propellant ignition.

In the original Metal Storm patents the propellant immediately behind the projectile closest to the muzzle of the gun barrel was ignited by an electronically fired primer, the projectile was set in motion, and at the same time a reactive force acted on the remaining stacked projectiles in the barrel, pushing them backwards. By design, the remaining projectiles would distort under this load, expanding radially and sealing against the gun barrel wall. This created a seal which prevented the hot propellant gases (expanding behind the lead projectile) prematurely igniting the remaining propellant charges in the barrel (blow-back). As each of these propellant charges was selectively (electronically) ignited, the force 'unlocked' the projectile in front and propelled it down the gun barrel, and reinforced the radial expansion (and hence the seal) between the projectiles remaining in the barrel and the barrel wall.

Subsequent designs discarded the 'distorting shell sealing against the barrel' concept in favor of containing the propellant in 'skirts' that form the rear part of each projectile. These skirted projectiles differ from conventional 'shells and cartridge' units in that the skirts are part of the projectile, and in that the skirts are 'open-ended' (at the rear). The rearward seal to the skirt is provided by the nose of the following projectile in the barrel. As in the previous design, the firing of a projectile results in a rearward impulse on the remaining projectiles stacked in the barrel. This results in the skirts of the remaining shells in the barrel being compressed against the following shell heads, effectively creating a seal that prevents hot gases in the barrel triggering unintended propellant ignition ('blow-back') along the length of the barrel. Metal Storm also introduced inductive electronic ignition of the propellant, effectively from outside the barrel. This overcame technical issues in maintaining physical contacts with the propellant charges, which due to the compression effectively 'shift' slightly backwards within the barrel during firing.

The skirt-to-nose joint has in recent designs incorporated an easy-release arrangement which allow the shells to be clipped together to form robust ammunition 'tubes' which can be transported more readily than individual shells, and inserted directly into Metal Storm barrels. Metal Storm have indicated the tubes can be 'pulled apart' and reconstructed in the field to make up custom combinations of ammunition, and to facilitate 'topping off' a partly discharged tube that is still in the barrel.

Features

The distinguishing features of this technology are the absence of ammunition feed and casing ejection systems (the only moving parts are the projectiles), and the electronic ignition of the propellant charges. The relatively simple external shape of the Metal Storm barrel allows for the clustering of Metal Storm barrels into a barrel array or 'pod', or for their attachment (as single units) 'bolted on' to existing weapons mounts, including infantry weapons. The absence of a mechanical feed mechanism and the inherently compact lightweight nature of Metal Storm systems also makes them suitable for attachment to light robotic ground and aerial vehicles. The electronic ignition allows for the firing of the stacked ammunitions at 'electronic speed' without any delays caused by mechanical ammunition feed mechanisms. The electronic firing also creates the potential for tighter integration with electronic targeting systems, with electronically programmable fuses in air burst ammunition, and with (in the case of hand guns) electronic grip recognition technology.

The clustered barrel array has been further developed with the design and building of prototypes of electronic firing control systems, allowing selective firing from any barrel in a cluster, and within each barrel the ability to control the rate of fire. This allows for responses which range from the equivalent of a volley gun discharge (all projectiles 'at once') to using (selectively) individual munitions with increasingly serious (but non-lethal) effects and lethal munitions including high explosive and air burst shells (all from different barrels in the array). The ability to deploy a range of munitions from effectively 'one' weapon system, and to selectively escalate responses from the non-lethal to lethal without reloading, has been put forward by the company as an advantage in urban warfare and insurgency situations where a range of responses may be quickly required in close quarter fighting and crowd control.

A patent exists for a design where the gun tubes at the edges of the array are angled outwards from the main axis so that a gun tube array mounted on a tracking platform would have the potential to engage a target before the bulk of the centrally located gun tubes reached the optimal aiming position. This feature, combined with the 'always loaded' nature of the technology, and the potential to rapidly produce a very high density (low distance of separation) of projectiles 'in the air' is put forward by the company as an advantage for this technology in close-in weapons support roles.

Manual, automatic and semi-automatic reloading concepts exist, incorporating breech and muzzle loading into permanent barrels, replaceable barrels (and barrel arrays), a belt-fed stacked-cartridge gun patent, and a patented breechless continuous feed gun with injected propellant. With the exception of the belt-fed and the breechless gun patents, all of Metal Storm's gun concepts are limited to bursts of no more than the number of projectiles pre-loaded into the barrel(s). That said, a barrel array might contain more projectiles in fact than a traditional 'clip' or 'belt'. Latest projectile designs (2007) incorporate a head to tail clip-together feature, allowing the rapid construction and deconstruction (in the field) of ammunition 'tubes' from individual shells. These tubes can be inserted directly (and locked) into Metal Storm barrels.

Products

Redback

The Redback weapon system is being developed under a teaming agreement with Electro-Optic Systems (EOS), Metal Storm (MS) and Singapore Technologies Kinetics (ST Kinetics). The Redback is a 4-barrel, 16-shot remotely operated weapon system that can automatically track targets and slew at speeds of up to 700 degrees/second (almost 2 complete revolutions per second). The primary role of Redback is as a lightweight vehicle or fixed asset mounted 40 mm weapon system. The Redback can utilize high explosive, enhanced blast, and air bursting munitions, all of which have been successfully test fired, as well as a suite of less-than-lethal munitions such as gas, smoke, sponge, CS (Capsaicin) and illumination. An enhancement to undertake autonomous engagement and intercept of multiple Rocket propelled Grenades (RPGs) is being developed and tested.

Firestorm

Firestorm is a light-weight, remotely-operated weapon system developed under an SBIR contract with the US Army in 2007. The 4-gun, 40 mm robotic weapon system is a versatile platform capable of firing a family of both lethal and less-than-lethal munitions including high explosive, airburst, flash-bang, payload (selectable CS, tear gas, and inert smoke payloads), frangible nose (selectable marking, inert or CS powders), and blunt impact foam rounds. As such, Firestorm provides a flexible solution to various situations and applications including area denial, fixed asset, crowd-control, vehicle protection and many other robotic applications. The Firestorm system consists of a robotic mount with controllable azimuth and elevation capability, a modular, drop-in gun pod, consisting of four electronically-fired, stacked-round, 40-mm launchers mounted in a recoil-mitigation cage, and a sighting and targeting package. The system is currently configured for plug-and-play operation, requiring DC power and an ethernet connection. System operation is simplified with an intuitive fire control user interface installed on any computer. Though still a prototype, the system has been tested and verified and continues to be optimized in anticipation of future production.

GLL4042

Core to the Firestorm weapon pod is the GLL4042 40 mm, electronically-fired, stacked-round launcher. With no moving parts, the weapon is invulnerable to mechanical failures such as jammed bolts, and broken firing pins. The launcher can achieve extreme rates of fire, surpassing those obtainable using traditional firearms. The cyclic rate of fire enables trailing rounds to be fired before leading rounds leave the barrel, resulting in projectiles spaced less than a foot apart in flight. The GLL4042 is capable of launching both lethal and less-than-lethal munitions, and offers round-detection capability for munition balance feedback to the user. The GLL4042 is not configured to be fired as a stand-alone weapon and requires direct connection using a military cable to the fire control unit. Linear magazines are pre-loaded with stacked munitions and breech-loaded into the launcher before fired. Several demonstrations of the product have already been performed to audiences including the army, navy and civilians.

3GL – 3 shot semi automatic 40mm grenade launcher

The 3GL is a 40mm semi-automatic 3 shot underslung grenade launcher that can be fitted to a soldier’s assault weapon. It carries less than 1lb additional weight penalty over a single shot M203 grenade launcher, while providing three times the firepower before reloading. 3GL allows the shooter to maintain eye contact with the target during an engagement which significantly increases the probability of hit. Further, the semi- automatic capability enables rapid multiple shots to first penetrate cover, such as a light armoured or soft skin vehicle, a window or door opening, then incapacitate targets inside. This capability is simply not achievable with a single shot system In February 2009 the 3GL achieved certification for safe man-firing using 40mm ammunition with non- explosive warheads. Qualification for man-firing using high explosive 40mm ammunition is currently in progress. Winning the fire fight on military operations is about the speed and immediate delivery of firepower onto a target and 3GL delivers significant advances in this area with both lethal and non lethal capabilities.

MAUL

The Multi-shot Accessory Under-barrel Launcher (MAUL) is an electronically-fired, 12-gauge shotgun for use as an accessory weapon to the M4 rifle. Immediately succeeding bench testing and verification of the concept launcher under a contract with the Marine Corp War Fighting Laboratory, follow-on funding to develop the prototype accessory weapon was awarded by the Office of Naval Research (ONR) in mid 2008. An emphasis on minimal weight, lean profile, and functional simplicity will dictate the design and fabrication of the completed weapon system. With a 5-shot, lethal and less-than-lethal (LTL) capability, the MAUL will offer versatility in special missions, military police, SWAT, and all-purpose defense applications.

Metal Storm reported the first shoulder-firing of the MAUL during tests on 2009-04-24 at its test facilities in Chantilly, Virginia.

36 Barrel Prototype

Metal Storm has created a 36-barreled stacked projectile machine gun, boasting the highest rate of fire in the world. This weapons system has a firing rate capability of slightly more than one million rounds per minute.

Limitations

Widespread public awareness of Metal Storm technology was due to media coverage in relation to the theoretical 1 million rounds/minute rate of fire. In the United Kingdom it was featured along with its inventor on the popular BBC show Tomorrow's World. As a result of this, and other publicity, there have at times been unrealistic expectations of the technology, particularly in regard to the ease with which such technology might be developed and implemented.

Some limitations with the technology became apparent during the late 1990s as development continued. Much of the detail of the technology remains classified but it is understood that:

• While the simplified mechanics and relative light weight of Metal Storm gun/barrel array suggested that they might have advantages when deployed on light unmanned aerial vehicles, it was anticipated that recoil management may become a significant issue relative to the light weight of the vehicle and consequently to flight stability. However, a Dragonfly Pictures DP-5X unmanned helicopter (in free flight) has since been demonstrated firing Metal Storm 40 mm weapons.

• High barrel pressures were noted in early testing when multiple shells were 'fired' so rapidly that the second (and subsequent) shells were in motion within the barrel before the first had left the muzzle of the gun. While this resulted in very high muzzle velocities it also (appeared) to cause concern about barrel wear and barrel integrity. Metal Storm took out a patent on a barrel pressure relief valve system; but has concentrated in recent years on the development of low pressure 40 mm systems, and has in recent demonstrations deployed a microchip at the barrel muzzle which detects the passage of each projectile and locks the firing mechanism (of each subsequent shell) until the first shell has cleared the muzzle. This still allows for much higher rates of fire than conventional weapons, but appears to guard against unintended high pressure situations in the barrels.

Financials and funding

The company was founded in 1994, listed on the Australian Stock Exchange in 1999 and on the Nasdaq in 2001. In mid-2008, Metal Storm received notice from the Nasdaq that the company was below the minimum threshold levels for market capitalization, shareholders equity and net income needed to maintain its NASDAQ listing. In response, Metal Storm removed its American Depositary Shares from the Nasdaq and relisted them on the U.S. Pink Sheets Market.

On February 28, 2008, Metal Storm's auditor, PricewaterhouseCoopers ("PwC"), issued an adverse going concern opinion regarding Metal Storm. Specifically, that Metal Storm has "Significant Uncertainty Regarding Continuation as a Going Concern." The reason cited by PwC is uncertainty whether the Company can "continue to comply with the terms of its Trust Deed in relation to the covenants set out for minimum cash levels." On May 19, 2008, Metal Storm announced that it was "giving consideration to extending the maturity date of its listed convertible notes from 1 September 2009 to a later date" and "raising approximately A$6 million by the offer of new convertible notes."

For details of the company's financial position please refer to the Metal Storm Annual Report, and the company's filings with the Australian Stock Exchange, the Australian Securities and Investment Commission and the US Securities and Exchange Commission.

Key personnel

Directors

• Terence James O'Dwyer, Chairman since September 2005
• Peter D. Jonson, PhD, Chairman since February 2006
• John R. Nicholls, Chairman since September 2006
• Lee John Finniear, PhD: Managing Director since May 24, 2007 & CEO since February 19, 2007
• Trevor William Tappenden, Chairman since July 1, 2008

Ex-directors

• Brigadier Michael Harris, Australian Army (retired), 1994-2000
• J. Brett Heading, Chairman, 1988-March 2003
• Brigadier Peter Pursey AM, Australian Army (retired), 1994-March 2003
• Kevin Dart, 1994-October 2003
• Lt General Daniel Christman, US Army (retired), June 2002-June 2004
• Admiral William Owens, US Navy (retired), 2000-May 2004, Chairman of the Board, November 2001-May 2004
• Charles A. Vehlow, CEO, March 2003-December 2004
• J. Dennis Heipt, October 2004-February 2005
• J. Michael O'Dwyer, Founder, Managing Director, CEO, Executive Director, Director of Scientific Innovation, Principal Technical Adviser (retired February 2005)
• David A. Smith, CEO, February 2005-May 2006
• Daniel Lewis Alspach, PhD, August 2003-July 2006
• General Wayne Allan Downing, US Army (retired), October 1999-October 2001, Deputy Chairman, October 2002-November 2006
• Bruce Sinclair McComish, October 2004-March 8, 2007
• James Michael Crunk, September 2005-May 23, 2008

Other key personnel

• Brett I. Farmer: Chief Financial Officer
• Peter R. Wetzig: Company Secretary
• Arthur David Schatz: Vice President - Business Development
• Peter D. Faulkner: Senior Vice-President – Director of U.S. Operations

Total Personnel

In a Form 20-F filing with the U.S. Securities and Exchange Commission dated June 30, 2008, Metal Storm reported that it employed 30 staff as of December 31, 2007.

Patents

• Metal Storm Patents at the European Patent Office
• Metal Storm Patents at the US Patent Office
• Metal Storm Patents at the Australian Patent Office

Patent holders

• J. Michael O'Dwyer
• John Ramon Bambach
• Sean Patrick O'Dwyer (J. Michael O'Dwyer's son)

International Interest

In October 2006, the Australian media and New Zealand media reported that Mike O'Dwyer had rejected a US$100 million offer by the Chinese People's Liberation Army to go and live in China, where he would have provided all of his knowledge, and that there had been other attempts to acquire the technology. Under Australian law, it would have been illegal for Metal Storm to sell the technology to the Chinese military, but it would not have been illegal for O'Dwyer to have gone to China to work for them. US and Australian Government military sources have stated that there are arrangements in place to prevent knowledge from being transferred.

In popular culture

Metal Storm plays an important role in the alternate-history novels of the Axis of Time trilogy by John Birmingham, as an important element in future naval close-in weapons systems and also in a combat rifle, the Remington G4.

The O'Dwyer VLe, a prototype Metal Storm handgun, is featured in the John Ridley novels What Fire Cannot Burn and Those Who Walk In Darkness

Metal Storm weapons mounted on the chassis of an M1A1 Abrams tank are featured in When the Devil Dances and Hell's Faire books by John Ringo as stand-alone weapons. They are also installed on the upper deck of the SheVa Self-propelled artillery vehicle 'BunBun' as an improvised secondary weapons system.

Metal Storm weapons were also mentioned (and used by the IG-88 bounty hunter team) in the Matthew Reilly action novel Scarecrow. They have a stated firing rate of 10,000 RPM.

The CSI: Miami episode 'Guerillas In The Mist' features a Metal Storm weapon called 'The Vaporiser', named for its apparent ability to atomise its targets.

See also

• List of modern armament manufacturers
• List of modern weapons
• Volley Gun
• Nordenfelt gun
• Machine Gun
• Close-in weapon system

External links

• Metal Storm Limited
• Metal Storm Limited Share Price Information
• Metal Storm live firing in US
• Transcript of interview with Mike O'Dwyer and others in 2000 (ABC)
• Metal Storm interview with Arthur Schatz, 8/2006
• [1] Metal Storm 36 barrel prototype test firing.
• [2] "Scientific American" Article on 9 mm Prototype
• MAUL and 3GL on Defense-update