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How to make ballistic gel?

How to Make Ballistic Gel

What is Ballistic Gel?

Before diving into the process of making ballistic gel, it’s essential to understand what it is. Ballistic gel, also known as Ballistics gel, is a simulation medium used to simulate the behavior of soft tissues in the human body during ballistics tests. It is typically used in shooting ranges and training facilities to measure the expansion and penetration of projectiles, such as bullets and arrowheads, to better understand their trajectory and potential for injury.

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Components and Ratio

To make ballistic gel, you will need the following components in the following ratio:

• 97.6% distilled water
• 2.3% surgical-grade gelatin (bloom gel strength: 225-235 g/tr)

Method of Preparation

The process of preparing ballistic gel involves the following steps:

Contents

Step 1: Bloom Gelatin

Bloom the gelatin according to the manufacturer’s instructions by dissolving it in warm water. For every 100 g of gelatin, you need to mix it with 400 g of distilled water. Bring the mixture to a temperature of around 40°C to 45°C (104°F to 113°F).

Step 2: Combine Distilled Water and Bloomed Gelatin

Add the bloomed gelatin mixture to 400 parts by weight of distilled water and mix thoroughly until it’s fully dissolved. Avoid air bubbles, as they can cause problems during the preparation process.

Step 3: Heat the Mixture

Heat the gelatin solution in a heat-resistant container or bowl at a moderate heat until the temperature reaches around 65°C (149°F) to 70°C (158°F). Make sure to maintain the pH level of the mixture, as high levels can lead to an unpredictable final product.

Step 4: Add Coloring and Fibrils**

You can add a colorant (blue dye works well) and small quantities of hair strands (as an analog of blood vessel) to simulate human tissues.

### **Step 5: Prepare the Gel for Setting**

Transfer the gel mixture to a well-mixed solution with continuous agitation until the desired gel structure is formed. Keep in mind that excessive aeration can hinder the development of a dense and transparent gel.

### **Step 6: Cool the Gel and Shape it**

Pour the cooled gel into the desired container and mold it to a flat rectangular shape (ideally, a slab measuring around 12.7 cm × 30.5 cm × 7.5 cm). Refrigerate or place the mold in the refrigerator at around 3°C to 4°C (37°F to 39°F) to prevent over-set gel formation. Monitor the cooling process; avoid overheating.

### **Step 7: Testing and Re-formulation (optional)**

It is essential to conduct small-scale experiments (1mm – 1 cm³ samples) of your ballistics gel at varying thickness and distances, noting changes and observing stability to perfect the process, or making small adjustments accordingly. Additionally, perform repeated temperature trials within a small test room environment for future comparison studies, for consistent ballistic studies

**Final Thoughts and Recommendations**

1. **Ensure correct ratios of ingredients**, maintain optimal heat control and uniform stirring processes during every stage to maximize results in producing an extremely effective simulative tool (Fig: A-Example 10, Ballistics Test in progress, **(link removed for anonymous mode – view page as an original 9**), see Ballistic Table
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