The Defence Research and Development Organisation (DRDO) has launched a project to develop polymer-cased ammunition (PCA) for small arms, marking a significant step towards replacing traditional brass cartridges with lighter, more durable alternatives for the armed forces.
The project is being undertaken by DRDO's Armament Research and Development Establishment (ARDE) in collaboration with industry partners. Initially, it will focus on ammunition for pistols, carbines and rifles before being expanded to larger-calibre weapons.
Unlike conventional cartridges, polymer-cased ammunition uses a high-strength polymer shell capable of withstanding the heat and pressure generated during firing. The base rim and the projectile remain metallic, while the polymer casing reduces the overall weight of each cartridge by around 25-30 per cent.
Defence experts said the lighter ammunition would reduce the load carried by soldiers, improve mobility in combat and simplify logistics by allowing more rounds to be transported without increasing weight.
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According to DRDO officials, the project aims to replace brass cartridges, which have remained the standard for military ammunition for nearly two centuries.
Besides being lighter, polymer casings are expected to reduce manufacturing costs and improve weapon performance by absorbing more heat than conventional brass cases. This helps prevent weapons from overheating during sustained firing and could enable troops to operate for longer periods without interruption.
Polymer-cased ammunition should not be confused with so-called plastic bullets used by law enforcement agencies for crowd control. While plastic bullets are generally non-lethal and use plastic or hardened rubber projectiles, polymer-cased ammunition fires conventional metal projectiles and is designed for combat use.
Although polymer ammunition has gained attention in recent years, particularly with the armed forces of countries such as the United States and Australia exploring or adopting the technology, its origins date back to the early 1950s, when polymers were first used in shotgun cartridges.
The brass cartridge that polymer ammunition is intended to replace traces its origins to the early nineteenth century. Over the decades, metallic cartridges became the global standard for military firearms. The new initiative reflects India's broader effort to modernise defence equipment through indigenous research and development while improving operational efficiency for frontline troops.
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