Tensylon®
Survivability Solutions
The ever-evolving threats faced by the military,
government agencies and law enforcement
today require the continuous research,
development and life cycle testing of innovative
survivability solutions, which have the highest
level of performance and offer the best value
in terms of weight and cost. BAE Systems has
made many breakthroughs in high performance
antiballistic composites including both opaque
and transparent technologies.
BAE Systems’ proprietary material, Tensylon®,
is a family of Ultra High Molecular Weight
Polyethylene (UHMW-PE) products, offering
significant advantages when compared to
other high performance materials including
para-aramids, UHMW-PEs and S-2 fiberglass.
Tensylon®offers distinct benefits in both
survivability and commercial applications. The
Tensylon®also has a “green” environmental
profile, requiring no environmental permits to
produce.
PRODUCT AVAILABILITY
BAE Systems offers a range of unique product
forms. These include woven microtape and
wider tape forms as well as bidirectional
composite materials utilized internally
exclusively to produce BAE Systems proprietary
survivability solutions.
security & survivability Systems
SURVIVABILITY APPLICATIONS
Spall Liner
Tensylon®was first used as a spall liner, in
more than 2,400 Caiman Mine Resistant
Ambush Protected Vehicles (MRAP). Tensylon’s®
performance as a spall liner in military ground
vehicles has been stringently tested and
combat proven. Tensylon®based composite
armor panels offer a significant reduction
in spall quantity and cone angle inside crew
compartments.
Ballistic Blanket
Tensylon®can be used as ballistic blanket
for military ground vehicles, commercial
armored vehicles and aircraft. Several levels of
certification have been achieved.
Appliqué Armor
Tensylon®is an integral component of the
leading value candidate for EFP and RPG defeat
and is fully qualified by Army Research Labs
(ARL) for appliqué armor applications.
Individual Protection and Other Applications
Tensylon®can be used for individual protection,
including helmets, hybrid and monolithic insert
plates and body armor. Tensylon®can also
be used in maritime and architectural armor
applications.
Tensylon®
Survivability Solutions

BENEFITS IN SURVIVABILITY APPLICATIONS

– Tensylon®is produced utilizing solid state extrusion
technology. This is simpler and more cost effective
than other conventional manufacturing methods
of UHMW-PEs, as it does not require dissolution,
solvent extraction or recycle unit operations. This
offers material savings of 25-40%, compared to
other UHMW-PE materials.
– Tensylon®is ballistically more efficient than typical
woven para-aramids utilized in military ground
vehicles, while offering weight advantages at
similar costs.
– Tensylon®anti-ballistic composites are made to
application specific widths to maximize material
yield. This results in additional cost savings of 25%
or more.
– Tensylon®has significantly greater flexural strength
and proprietary composite formulations, resulting
in less delamination important in overmatched
threat situations.
– Tensylon®meets and exceeds all specifications
for spall liners (FMVSS 302; FAR 25.853; and
BSS 7238, 7239) at similar costs and lower
areal densities than MIL-DTL-62474 compliant
composite laminates.
– Tensylon®ballistic performance is insignificantly
affected by extreme temperatures (-65° to 180° F).

For more information contact:

This document gives only a general description

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