Creating something from nothing using Technology is a cool thing. Nowhere is this more evident than with additive manufacturing. What is additive manufacturing? That’s a great question and one we will dive into. For now, just think of it as 3D printing on steroids. One thing is certain. Additive manufacturing techniques are revolutionizing the suppressor industry, not just because of what the end product is, but also because of what it allows the engineer to create.
What is additive manufacturing?
Take the concept of additive manufacturing and try to explain it. In the past, one might be accused of magic. It is a kind of magic, though, in a way. Take some powder, flash some light at it and **poof** you get an object. What it really is, however, is very much like 3D printing without the waste.
Products like the BANISH 9K and the new BANISH 12 suppressors use of this type of manufacturing for some truly revolutionary products.
Let’s cover the basics. A very precise laser hits a layer of powdered metal, bonding the powder molecules, also known as direct laser metal sintering (DMLS). These layers are very thin, at just 40 microns. That is .0015748 inches to give you some perspective. Another layer adds on as the laser bonds them.
Additive manufactured products, like BANISH suppressors, have no excess materials. The finished product is exactly what it is. The process is more efficient and effective.
Durability is not a concern, either. A BANISH suppressor made through the DMLS process has metal integrity that has more than 99-percent solid density. This has the same relative density for any metal alloy. The product confidence is the same for any other suppressor.
Why go this route?
The BANISH 12 is a great example of how additive manufacturing allowed the engineering team to play with the available space to cut down on weight while still getting optimal performance.
Geometry is the main reason to develop a product through additive manufacturing according to Lukas VanLaecken, the Director of Engineering for BANISH Suppressors
“One of the main things that this type of construction process allows us to do is really explore the geometry of a product,” he said. “We can really make the absolute most of the available space and create intricate patterns for support and truly optimize the reductions in sound, recoil and weight from a product.”
A smile crept across VanLaecken’s face as he talked about the many ways he can play with geometry when designing a product for this manufacturing application.
“Just knowing what we can build inside of a shape and have that be supported and be a strong component without additional processes or steps to get it built right is very freeing as an engineer,” he said.
An example he used are bars inside of the BANISH 12 suppressor that allow the shot wad to travel from the shotgun muzzle to the choke tubes. Other shotgun suppressors had to have each similar construction assembled in place individually, creating more weight and less efficiency.
While there are several variations, a printed suppressor is one made using a method where metal powder is welded into a specific shape using a computer-guided laser.
The most common metals used in DMLS suppressors are stainless steel, aluminum, titanium, and Inconel. Currently, BANISH uses titanium and Inconel for its printed suppressors.
Yes, like any homemade suppressor, you can legally make and own it as long as you file the Form 3 paperwork with the ATF.
Both manufacturing techniques have their advantages. Printed cans are usually lighter and can have more compact designs. Welded suppressors are serviceable and repaired easily. Both have their place.
Yes, you can count on BANISH to release more additive manufacturers suppressors for rifles, pistols and shotguns in the near future.
Suppressors?
A suppressor made with additive manufacturing is really a work or geometric art created using computers, space-age metals, and lasers. Photo by Silencer Central
Are suppressors new technology? No. The first suppressor was marketed in 1902 after being invented by Hiram Percy Maxim. There is even a theory being floated that the silencer played a role in the development of the automotive muffler. Maxim even produced some for a time. This is not new technology.
A suppressor routes the gases from ammunition discharge through a series of baffles, cutting the sound output. Most suppressors redirect the sound waves into these baffles and then use the waves themselves against each other to cancel out the sound output.
Additive manufacturing builds the suppressor as a single unit. This is where it gets really cool, and geometry becomes an art form. This is how suppressors are cutting edge stuff. The baffles are now part of the interior design.
Decibels are the common unit we use for measuring the relative intensities of sound. The decibel scale is logarithmic, meaning a sound with an intensity that is twice that of a reference sound corresponds to an increase of little more than three decibels.
A suppressor reduces the sound output of a gunshot to a decibel level below the threshold for hearing damage, which is 140 decibels.
Why talk about decibels here? Decibels are at the core of every aspect of suppressor design. The added features of recoil reduction and increased accuracy are a happy bi-product of sound suppression.
Decibel reduction is a big part of any suppressor design.
Additive manufacturing processes allow the designer to explore how the shape of a chamber can affect the sound wave. The interior of a DMLS suppressor has no extra materials to affect the sound wave travel. Welded suppressors can have additional braces and other projections that can have an impact on how the sound wave reverberates through the suppressor.
What is next?
VanLaecken said using this process to manufacture suppressors opens up a lot of territory that is currently unexplored.
“There are a lot of materials that are in use in the Aerospace industry that are not currently being used in suppressor manufacturing,” he said. “Additive manufacturing opens the realms of possibilities for different exotic materials that we can now explore using. I am really looking forward to what the future holds for our new product designs.”
While many suppressors can be used on several different caliber firearms, we have some specific models that can make your shooting more enjoyable. Pick the caliber that you have in mind. If you don’t see your caliber, pick one close to it to see our recommendations.
