The global defense industry has experienced steady growth over the last decade. Rising geopolitical tensions and efforts toward modernization across various militaries are driving this expansion. Projections indicate an annual growth rate of 8.2% until 2030. In the U.S. alone, the defense budget stands at $824 billion, marking a 3% increase from 2023.

As part of the ongoing modernization, there’s a growing trend of replacing components traditionally made from metal with polymers. The benefits include reduced maintenance, lighter weight, corrosion resistance, and in some cases, improved performance.

Challenges of Working with the Defense Industry

Rion and its subsidiary Plastokit have long-standing expertise in working with the defense industry in both Israel and the U.S. Throughout this time, we have encountered demanding requirements not found in other industries.

“The process is lengthy and complex. First and foremost, the background of the manufacturing company must be thoroughly vetted. There are multiple certifications and regulatory approvals needed to qualify as a supplier and buyer in Israel and the U.S.,” explains Omer Kraus, Plant Manager at Plastokit. “From the moment a customer order is placed until production and delivery begin, the process can take up to a year, and that’s after the company has been qualified as a certified supplier.”

Plastokit has obtained all necessary certifications and is officially an authorized supplier in the U.S. We provide in-depth training to our employees and conduct strict oversight to ensure that the detailed instructions are carried out properly. “Beyond standard procedures, the U.S. military has specific guidelines,” notes Omer, “such as how to mark products according to American standards.”

Collaboration with Raytheon to Produce Dummy Rounds

We have been working closely since the ’90s with our main client in the defense industry, Raytheon, on a project for the U.S. Navy. “Our collaboration started when we were asked to manufacture dummy rounds for the 20mm Vulcan cannon. Navy ships aren’t allowed to enter ports with live ammunition, and each Vulcan cannon requires a 1000-round ammunition belt to remain balanced. As such, 1000 dummy rounds are needed for each cannon, and every ship has at least two cannons. The military requested that we replace the aluminum dummy rounds previously used with plastic ones, which require minimal maintenance,” recalls Amos Shavit, Plastokit’s former Chief Engineer, now retired and serving as a plastics consultant for the company. “The dummy rounds had to match the weight and center of gravity of live rounds.”

Dummy Rounds

The development process involved several iterations in which we successfully overcame complex technological challenges. “We faced difficulties with sinking areas, product centering, and ensuring wall thickness matches the U.S. military’s exact specifications. The dummy round needed to simulate a live round but, of course, not explode,” Amos adds with a smile. “We developed the round in close collaboration with the military, which included on-site tours of our plant. We suggested modifications to address certain challenges, all of which were accepted.”

We also faced logistical challenges. The product consists of 100 dummy rounds packed into an ammo box, which are then linked together in ammunition belts before being loaded into the cannon. We were required to purchase the ammo boxes and ammunition belts ourselves, ensuring no component was missing. Any deviation from the specifications or error in the number of rounds is critical, so we developed methods to prevent such mistakes. Additionally, we had to thoroughly review and understand dozens of regulations before production could even begin, alongside maintaining the quality and diversity of the insulation and packaging materials.

2 Million Rounds without a Single Complaint

“There’s a question the U.S. military asks before placing a production order to assess the company’s commitment to long-term production—are you sure you’ll make a profit?” Amos recounts. “We were confident. Over the years, we’ve delivered 2 million dummy rounds to all American ships worldwide, and we’ve never received a single complaint or comment—whether about timing or quality. Much of the success is owed to Yigal Zeligman, may he rest in peace, who made sure nothing was ever lacking during production.”

A Close up on Dummy Rounds

Success with the U.S. military also drew interest from Israel as well. “The Israeli Navy uses Vulcan cannons similar to those of the U.S. Navy and it decided to purchase dummy rounds for all the ships in its fleet, including future ships. We made direct shipments to the Haifa port,” says Omer. “We continue to supply dummy rounds for the U.S. military through Raytheon, the manufacturer of the Vulcan cannons, in addition to working with other clients.”

Choosing Rion for your Defense industry needs

Our ability to deliver high-quality products stems from our approach to development and production. We oversee every stage, from initial product design to mold creation, injection molding tests, and strict quality control. This process consistently delivers high-quality results. We are fully involved in the product development process, tailoring our production to the client’s exact specifications, including precise adjustments of strength and density. Our commitment to our clients is also reflected in short delivery times and competitive pricing, without compromising on the high standards and precision required in the defense industry.

We take pride in its long-standing expertise in manufacturing advanced plastic and composite materials. As part of our commitment to excellence, we operate a dedicated department for process development and optimization. Our strength also lies in our advanced automation capabilities, which are integrated into both production and quality control processes. The cutting-edge tools at our disposal enable us to deliver precise, high-quality solutions for products that require exacting standards.

“The ability of a factory to handle a project of this scale depends on its organizational culture—everyone at the plant needs to be fully engaged in the work. Whether it’s management, quality control, or the production department, everyone needs to understand the requirements and receive the necessary certifications,” explains Omer. “Harmonious cooperation between all departments and attention to every detail is critical as well. Only in this way can we deliver a high-quality product that meets all the client’s demands.”