NON-LETHAL SYSTEM FOR TRAINING FOR LAW ENFORCEMENT AND MILITARY PERSONNEL
Unit Solutions approached NOVO to help them salvage a three-year program to develop a non-lethal, mil-spec, training system for law enforcement and military personnel. Unit Solutions explained that a non-lethal, but highly authentic, system would allow personnel to train in much more realistic settings, without the expense and restrictions associated with live fire training. The concept was to avoid unintended casualties through better training. We normally focus on medical device, life sciences, and printer systems, but once we understood the potential benefits of Unit Solution’s responsible approach, we were happy to support them.
ABOUT THE SYSTEM
The UNIT4 system is classified as a non-firearm, but otherwise provides an extremely realistic experience. The system uses a cassette with non-lethal marking rounds that are propelled with CO2. The marking rounds provide feedback on accuracy. They are biodegradable and non-toxic. The cassettes are interchangeable like conventional magazines. Size, weight, dynamics, balance, and operation are designed to mimic reality. The system cannot be converted for use with live rounds.
ENGINEERING CHALLENGES
The primary technical challenges arose from the need for accuracy, reliability, safety, and durability. In real-world environments, we could expect dirt, moisture, impact, and general rough handling from users. Trajectory had to be consistent and accurate. The mechanisms had to be reliable and capable of high frequency operation in auto mode under all conditions. We developed custom automation for loading cassettes and all necessary jigs and fixtures for assembly and quality control. We also provided complete production design documentation for manufacturing, assembly, and testing.
There was an even bigger challenge however. When Unit Solutions approached us, they acknowledged that the product had performance, documentation, and supplier issues. Essentially, the product had been designed, but not engineered. It took a year to address the engineering and supply chain issues and to stabilize the design in manufacturing. NOVO followed a systematic approach, justifying each design change with engineering analysis and bench testing. The Unit Solutions team quickly understood the benefits of this approach and became willing and enthusiastic partners in the development. After rigorous lab and field testing of the completed design, they were confident that their products would fulfill their marketing claims and meet the needs of their demanding customers.
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