Military vehicle insulation for heat, noise and vibration protects warfighters and equipment against conditions that can stop land systems in their tracks. These composite structures are used in engine bays, doors, floors, side panels and hatch covers. Casual observers notice a vehicle’s armor and weapons, but design engineers and manufacturers understand that custom insulation also supports the mission.  

Materials for Military Vehicle Insulation

Military vehicles need foams, films, facings and other materials for demanding conditions. For example, the diesel engines that power military land systems run hot and loud. If excessive heat and noise pass through the firewall and enter the crew compartment, warfighters may experience more than just distractions and discomfort. High heat and vibration-induced noise can also interfere with on-board electronics.

Thermal insulation for engine bays is fabricated from melamine foams, polyimide foams, and fiberglass composites with aluminum foil facings. In addition to reflecting radiant heat, aluminum foil provides a moisture barrier. Depending on the materials of construction, custom engine bay insulation can withstand washdowns with soapy water or the splash of automotive fluids.

To defend against noise and noise-induced vibrations, thermal management materials can be joined to sound-absorbing acoustical foams and vinyl sound-blockers. With the right rubber, thermal-acoustic insulation for engine bays can even resist the spread of flame and fire. Inside the armored vehicle, vibration mounts help to protect military electronics and instrumentation.

Yet the need for specialty insulation doesn’t end there. Sound absorbers and sound blockers are also used inside the crew compartment. Rubber floor mats and flooring stop sounds while protecting warfighters from slip-and-fall hazards. Custom rubber matting is also used in an armored vehicle’s equipment compartments to protect contents from vibration or movement.         

How Military Vehicle Insulation is Made

At Elasto Proxy, military vehicle insulation is fabricated by using these manufacturing processes.

  • Lamination joins different types of materials into a sandwich-like structure
  • Water jet cutting makes precise cuts, including chamfers, without tooling
  • Taping makes custom insulation easy-to-install for temporary or permanent fastening

Value-added services such as kitting, custom packaging, parts marking, and testing are also available.

Lamination requires precision so that sheets of thermal and acoustical materials align properly and form composite materials with strong, reliable bonds. Water jet cutting makes fine, fast cuts to these multi-layer materials – and without paying for or waiting for tooling. It’s ideal for both quick-turn and low-to-medium volume fabrication. Compared to hand cutting, water jet cutting also maximizes material yields because there’s less material waste.

Custom insulation that’s taped with a pressure-sensitive (PSA) adhesive facilitates ease-of-installation on the assembly line or at maintenance facilities. Installers like this peel-and-stick solution and can save even more time with military vehicle insulation that’s marked, kitted and custom packaged. With this value-added service, all of a vehicle’s insulation arrives in the same box with the insulation to install first on top. Parts marking supports the inclusion of information like the part number and manufacturing date.  

Testing Military Vehicle Insulation

Custom insulation for military vehicles requires careful testing, however. For example, MIL-STD-1474E from the U.S. Department of Defense specifies the maximum permissible noise levels produced by military land systems. In addition to supporting speech communications in noisy environments, MIL-STD-1474E seeks to minimize the risk of permanent noise-induced hearing loss.

Elasto Proxy combines material selection, expert fabrication, kitting and custom packaging with testing services for military vehicle insulation. For example, if you need custom insulation that reduces noise by a specific decibel level, we can make and test a solution that meets this requirement. We can also source and fabricate acoustical foams that absorb or block sounds at specific frequencies.

Get Samples of Military Vehicle Insulation

If you plan to attend CANSEC 2019, visit Elasto Proxy in Booth 913 to see samples of military vehicle insulation. You can also receive samples when you request the Elasto Bag on-line. This cinch-bag contains custom-fabricated engine bay insulation and cabin insulation that you can hold in your hand. It’s a great way to learn more about options for sound absorbers, sound blockers, flooring, and foil-faced

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