US Army unveils SixPAC polymer ammo packaging, first major update since WWII
The US Army has introduced SixPAC, a lightweight polymer ammunition packaging system for small-caliber rounds, replacing traditional wooden and metal cases used since World War II. Developed at Picatinny Arsenal, the polymer containers weigh about half as much as legacy steel versions, reducing soldier burden and improving mobility. Designed initially for 6.8mm cartridges, the system underwent soldier testing through 2024-2025, with over 800 US injection molders expected to produce the crates.
Editorial responsibility
- No named human review is recorded for this page.
- Reports are grouped by semantic similarity and deterministic rules. Language models may assist titles, summaries, translation and cross-source analysis; the page itself is projected from evidence records.
- Current automated evidence projection
Cross-source coverage
Wire timeline
Army pivots from WWII-era ammo cans toward polymer cases and 3D printing
The U.S. Army is introducing the SixPAC, a polymer ammunition container designed to replace traditional metal ammo cans that have been in use since World War II. Developed over a decade at Picatinny Arsenal, the new 6.8mm round container weighs about 2.8 pounds, roughly half the weight of its predecessors. Officials cite supply chain vulnerabilities as a key driver, noting that only two U.S. suppliers existed for metal cans, while over 800 injection molders can produce the polymer version. The SixPAC is currently a proof of concept for the Next Generation Squad Weapon, with plans to eventually adapt it for legacy calibers like 5.56mm and .50 caliber. The Army is also exploring 3D printing as a stopgap solution for emergency ammo can production during surges, with research slated to begin next fiscal year. Extensive ruggedness testing is underway, including temperature extremes from -65°F to 160°F, drops from vehicles and ships, and user evaluations at multiple Army installations.
Army replaces WWII-era metal ammo cans with polymer cases and 3D printing
The U.S. Army is introducing the SixPAC, a polymer ammunition container designed to replace the traditional metal M2A2 ammo can that has been in use since World War II. Developed over a decade at Picatinny Arsenal, the new container is about half the weight (2.8 pounds) and can be manufactured by over 800 U.S. injection molders, addressing supply chain vulnerabilities from a limited number of metal can suppliers. Initially designed for the 6.8mm rounds of the Next Generation Squad Weapon, the Army plans to eventually adapt the polymer cases for legacy calibers including 5.56mm and .50 caliber. The SixPAC is undergoing rigorous testing including temperature extremes from -65°F to 160°F, drop tests from vehicles and ships, and user evaluations at multiple Army bases. Additionally, Picatinny officials are researching 3D-printed ammunition containers as a stopgap solution for production surges, with research slated to begin next fiscal year.
US Army's Polymer 'SixPAC' Ammo Crates to Replace Legacy M2 Metal Ammo Boxes
The U.S. Army Combat Capabilities Development Command Armament Center has introduced a new polymer ammunition packaging system called 'SixPAC,' marking the first major overhaul of small-caliber ammo packaging since World War II. The SixPAC system features two lightweight polymer ammunition containers housed in a steel outer pack, designed to hold the new 6.8x51mm common cartridge (2.77 Fury). The polymer containers weigh half as much as legacy steel ammo boxes, reducing the load on soldiers. The system also eliminates wooden crates, which were manually assembled and susceptible to mold, replacing them with polymer components that simplify logistics and reduce environmental impact. More than 800 injection molders across the U.S. are expected to produce the crates, lowering costs and expanding the supply base. The Army plans to adapt the system for legacy small-caliber ammunition production lines after successful implementation with the 6.8mm cartridges.
Show 2 older updatesHide older updates
US Army unveils new lightweight small-caliber ammunition packaging
The US Army has revealed SixPAC, a new lightweight packaging system for small-caliber ammunition, marking the first major update since World War II. Developed by the US Army Combat Capabilities Development Command Armaments Center, SixPAC consists of two polymer ammunition containers housed within a steel outer case, replacing traditional wooden cases that were prone to mold and degradation. Initially designed for 6.8 mm cartridges, the system will be phased into existing production lines. The polymer inner containers weigh approximately half as much as current steel versions, reducing soldier burden and improving mobility for weight-restricted platforms like aircraft and watercraft. Manufacturing via injection molding could expand the supply base to over 800 potential US suppliers. The system underwent soldier testing throughout 2024 and into 2025, with ongoing design refinements based on feedback. Multiple container designs are under evaluation with continued investment and industry collaboration expected.
US Army Unveils SixPAC Lightweight Polymer Ammunition Packaging
The US Army has introduced SixPAC, a new lightweight ammunition packaging system for small-caliber rounds, marking the first major update since World War II. Developed by the US Army Combat Capabilities Development Command Armaments Center, SixPAC replaces traditional wooden cases with two polymer containers housed in a steel outer case. Initially designed for 6.8 mm cartridges, the system aims to reduce soldier burden, improve mobility, and eliminate issues like mold and manual assembly associated with wood. The polymer inner containers weigh about half as much as existing steel versions, benefiting weight-restricted platforms like aircraft and watercraft. Manufacturing via injection molding could expand the supply base to over 800 US suppliers. The system underwent soldier testing throughout 2024 and into 2025, with ongoing design refinements based on feedback. Multiple container designs are under evaluation, with continued investment and industry collaboration planned.