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Design Engineering

O’Gara utilizes 3-D Computer Aided Design (CAD) combined with past testing experience to ensure 360 degree protection with no ballistic gaps.  The process starts with CAD data of the base vehicle body either provided by the OEM or through laser scanning of an existing body.  Our designers then create models of each armored area forming it to the approximate contour of the base vehicle body.  The 3-D CAD models allow use of shot line and vulnerability analysis to ensure potential bullet or projectile pathways are all covered.  These 3-D models are then used to generate detailed drawing of parts or subcomponents for fabrication.  Design engineers also collaborate with manufacturing and quality engineers during the process to ensure that the final design can be built efficiently and with repeatable processes for quality assurance. 
Perhaps even more important than the design of an armored vehicle is the integration of armor materials.  Integration into a complete cab, hull or existing platform can mean life or death for the occupants of armored vehicles.  Armor integration is what separates excellent from good, and integration experience is what separates O’Gara designers and technicians from other companies that claim to offer protected vehicles.  O’Gara takes a whole approach to armor integration to include multiple integration elements in both the design and manufacturing stages:

  • Material Selection - Selecting the right material for the right threats and the right areas of the vehicle
  • Part shape and configuration - Designing each part as an interlocking system with excellent coverage and minimizing interfaces
  • Part interfaces and overlap - Making sure seams and joins are as strong and well protected as the primary materials
  • Part joining - Using approved processes for welding, bonding and mechanical fasteners
  • Framing - Building strong frames for transparent armor and other critical components that need enhanced edge protection
  • Armor Returns - Creating armor parts perpendicular to the primary surfaces to eliminate gaps between primary surfaces
  • Gap reduction and elimination - Using 3-D CAD and years of testing & manufacturing experience to ensure full 360 deg. coverage
  • Environmental considerations - Selecting the correct materials and joining methods to perform and last through harsh environments
  • Automotive considerations - Building the armor at appropriate weight and interfaces to ensure total automotive performance