Design & Engineering

Center of Gravity

Alpine Armoring’s Design & Engineering team makes certain and adheres to the fundamental principle that the stability of an armored vehicle requires optimizing the new point of the final center of gravity of the completed vehicle. They conduct technical assessments to lower that point when applicable, with the goal of achieving the best performance and handling while offering the most stable armored vehicle for the client, whether driven on a paved or off-road.

One of the key factors that determine how properly and professionally a vehicle is armored is when the vehicle’s center of gravity is correctly measured before and after the conversion.

Stress Analysis on Chassis

Alpine Armoring’s Design & Engineering Team sets itself apart from competitors by performing stress analysis on each vehicle chassis both during and after the completion of work. This allows for more strategic use of ballistic materials and a chance to improve the handling and rigidity of the whole capsule when the occupants ride in vehicle. That’s one more reason why our clients consistently rate Alpine Armoring’s vehicles as the best driving/handling vehicles in the industry.

3D simulation model with color-coded stress distribution on two structural beams. Pink vectors indicate direction and magnitude of forces. Color scale on the right denotes varying stress levels.

The most important aspect of an armored vehicle is how collectively protective AND safe it is. While that does include resistance to gunfire of different rounds and power, it also includes the driving and handling characteristics of the vehicle with added weight.

Finite element analysis (FEA) model of a G63 vehicle body structure showing stress distribution in various colors and vectors representing stress magnitudes.

Opaque Armor

Alpine Armoring takes pride in using a broad range of high-grade, certified ballistic opaque materials applied throughout the body of the vehicles.

In addition to ballistic steel, a combination of lightweight composites including ceramic armor, Kevlar®, Dyneema®, and Spectra® are often used in selected model SUVs and sedans. Continuous in-house ballistic testing of the materials is conducted to determine how they will hold up under extreme lines of fire using various high-power weapons and different grain/velocity rounds.

Ballistic Ceramics

In designing the perfect armor-retrofitting body of certain makes and models of a vehicle, Ballistic Plates armoured plate steel remains the choice for the opaque material. The composite ballistic material (ceramic armor in this case) is incorporated into armor-manufacturing of the vehicle. Ceramic is significantly lighter than steel yet preferred for certain vehicle armoring applications with varying results. In such cases, either Aluminum Carbide, Silicon Carbide, or Boron Carbide are typically considered in our manufacturing, as deemed suitable for any specific application.

A square tile labeled "S-2 Glass, Silicon Carbide Tile" with net-like texture and a small emblem in the center.

Ballistic Aramid Fiber

A woven type of “ultra-malleable” light-weight fabric aramid (i.e., Kevlar®) that can be shaped perfectly into seams and corners of the vehicle for lower-level protection, and back-splashed with ballistic steel or ceramic to achieve higher protection.

Ballistic Polyethylene

A specially laminated polyethylene composite material (i.e., Dyneema® and Spectra®) with light weight characteristics that’ is typically about 20%-25% of the weight of same size ballistic steel. However, aside from its higher price than ballistic steel, polyethylene is considerably thicker, thereby, on selected model SUVs and sedans, it would make it challenging to retrofit it properly and add the upholstery on the armored door panels matching the OEM fashion. Alpine Armoring’s unique and patented technique in incorporating this material into many of our armored vehicles achieves lighter weight and much better results at the end.

A panel showing bullet impacts from a 9mm, .22 LR, and .45 Auto firearms, labeled with the corresponding ammunition types and impact details.

Ballistic Steel

In the industry of armoring any type of armoured vehicles, for opaque material, armored plate steel of different Brinell scale and hardness (whether AR500, AR550 or AR600, or even MIL A 12560 or MIL A 46100), including Armox® from SSAB at different HBW standards (Hardness Brinell Wolfram) tested with varying tungsten carbide, remains the most preferred choice of applied in armoring vehicles. While Alpine Armoring ‘s manufactured armored vehicles could offer protection as high as .50 cal (.50 BMG at 12.7 x 99mm NATO) that is Alpine’s level A12 and beyond, including levels CEN B7, NIJ III & IV, and STANAG II/III), the majority of our vehicles are armored at level A9 with the ballistic steel being approximately 1/4” or 5/16” thick. Alpine Armoring frequently incorporates only the certified ballistic hardened steel, often the lightweight ballistic steel in conjunction with other composite ballistic materials to achieve the optimum lightest offered to its discerning clients in the world expecting the most intelligently engineered armored vehicles in the market. The majority of Alpine’s armored vehicles are armored at level A9 (B6+) with the ballistic steel being approximately 1/4” or 5/16” thick offering protection against most high-power assault rifles.

A black armored steel panel labeled "Alpine Armoring" with multiple bullet impact marks and test data written on it.

Transparent Armor

Through decades of experience and exclusive relationships with selected high-quality ballistic transparent/glass material manufacturers, at Alpine Armoring we have meticulously designed our no spall glass incorporating varying polycarbonate layers for each make and model vehicle with zero imperfections to significantly prevent or minimize any future delamination (a common occurrence in ballistic armored transparent material) while maximizing the optics of armored glass.

A thick glass panel with multiple visible impact points and cracks is shown, demonstrating resistance to penetration.

Alpine’s material science engineers are currently developing a new polyurethane compound that will decrease the thickness of armored glass. Visit our Ballistic Testing page for more details.

Vehicle Dynamic Testing

Because our finished armored vehicles are driven for both daily, on-road driving as well as extreme, off-road conditions, vehicle dynamic tests ensure optimal performance.

SUSPENSION

Alpine Armoring’s engineered armored vehicles offer extensively designed suspension systems with different components to ensure ideal mobility, stability, and crew comfort, under many challenging operational conditions, given the added weight. Alpine’s exclusive system of vehicle dynamics are designed and retrofitted to support the heavy weight of armored vehicles while navigating diverse terrains ranging from rugged landscapes and off-road driving to normal urban environments on paved roads. We incorporate advanced technologies such as hydropneumatics, torsion bars, and/or coil spring, specifically tailored to absorb shocks and vibrations effectively. By distributing the vehicle's weight evenly across multiple axles, Alpine’s suspensions enhance traction, minimize wear on tires, and facilitate smoother rides, crucial for both tactical maneuvers and long-distance travel.

BRAKING

Alpine Armoring conducts rigorous braking tests and slalom, or Moose tests to ensure the utmost safety and performance of the finished armored SUV, sedan, pickup truck, van or any other small or large trucks. These tests are meticulously designed to evaluate the braking efficiency and response time under various weather and road conditions. Prior to delivery of a vehicle to a client, Alpine’s armored vehicles are subjected to a series of controlled deceleration trials on different terrains, including asphalt, gravel, snow and wet surfaces, to simulate real-world scenarios. Advanced data acquisition systems are applied to monitor and record braking distances, pedal force, and overall stability during sudden stops. The results of these tests have provided Alpine Armoring critical insights, allowing us to refine our braking systems and ensure that our normal or custom-armored vehicles deliver the most reliable and responsive stopping power, even in the most demanding situations.