Ballistic Helmet Mounting Rail

Name: Helmet Gear Rails for Combat Field Equipment - Frigate
Price: 249.00 USD
Availability: InStock

Ballistic Helmet Mounting Rail supports MIL-STD-1913 and ARC interfaces, allowing direct attachment of electro-optical devices, illumination modules, and communications gear without auxiliary adaptors. This reduces interface mismatches across joint service configurations and supports standardized load-out interoperability.

Material Specification

7075-T6 Aluminum (MIL-A-22771) or Grade 5 Titanium (AMS 4928)

Dimensional Accuracy

±0.05mm (rail interface), ±0.1mm (structural)

Surface Finish

Ra ≤ 0.8μm (rail grooves), ≤1.6μm (mounting surfaces)

Hardness Requirement

150-160 HB (Aluminum), 34-38 HRC (Titanium)

Impact Resistance

Withstands 15J impact (MIL-STD-662F)

Product Description

Ballistic Helmet Mounting Rail incorporates topology-optimized strut geometry to distribute torsional and shear forces along defined load paths. This prevents flex-induced misalignment under eccentric accessory mass, maintaining rail rigidity during rapid motion or weapon recoil events.

Weapon Rail Interface Compliance

MIL-STD-1913 Picatinny Rail (STANAG 4694)

Certification Standard

MIL-STD-810G, NIJ Standard-0106.01

Non-Destructive Testing (NDT)

100% Visual (MIL-STD-2071), 10% MPI (ASTM E1444)

Corrosion Resistance

Type III Hardcoat Anodized (MIL-A-8625) or Nitride Coated

Attachment Load Capacity

50lb static load (22.7kg) with ≤1mm deflection

Technical Advantages

Ballistic Helmet Mounting Rail features a reduced cross-sectional contour with undercut geometry to minimize wind drag, foreign object snag risk, and frontal signature. The rail maintains aerodynamic efficiency without compromising accessory mounting stability.

Ballistic Helmet Mounting Rail is manufactured using continuous fiber-reinforced thermoplastics with high specific modulus and thermal dimensional stability. This composite formulation ensures structural integrity under high-temperature operating conditions and ballistic shock loads.

Let's Get Started

Need reliable Machining for your next project? Get in touch with us today, and we’ll help you find exactly what you need!

Industry Applications

Night Vision System Integration

Ballistic Helmet Mounting Rail enables stable mounting of monocular and binocular NVGs with minimal optical axis misalignment during dynamic operations.

Infrared Marker and Beacon Attachment

Ballistic Helmet Mounting Rail supports precise placement of IR strobes and beacons for team identification in no-light and low-light environments.

Head-Mounted Communication Equipment Support

Ballistic Helmet Mounting Rail provides structural anchoring for boom microphones, bone-conduction headsets, and signal routing modules in noise-isolated conditions.

Flashlight and Illumination Device Mounting

Ballistic Helmet Mounting Rail secures tactical flashlights with fixed orientation to maintain beam alignment under mechanical shock and vibration.

Heads-Up Display (HUD) Integration

Ballistic Helmet Mounting Rail supports HUD devices with fixed field-of-view alignment critical for augmented situational awareness and navigation overlays.

Camera and Recording Equipment Interface

Ballistic Helmet Mounting Rail accommodates POV and thermal cameras used for ISR (Intelligence, Surveillance, Reconnaissance) and mission documentation requirements.

Vibration Damping Architecture

Ballistic Helmet Mounting Rail integrates elastomer-embedded contact surfaces and preload-biased engagement interfaces to attenuate mechanical vibrations. This reduces micro-motion between mounted devices and rail, preserving targeting precision and electronic stability.

Ballistic Helmet Mounting Rail is designed for tool-less installation with mechanically indexed locking points. The architecture permits rapid field replacement or reconfiguration without requiring calibration, torquing, or wear-prone threaded fasteners.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does Frigate ensure dimensional accuracy for Ballistic Helmet Mounting Rail interfaces?

Frigate uses multi-axis CNC machining and coordinate measuring machines (CMM) to maintain tight tolerances across all rail mounting surfaces. Each part is validated against 3D helmet shell profiles to ensure proper contact. Tolerance stack-up is controlled within ±0.05 mm. This prevents accessory misfit and ensures consistent mechanical engagement.

What testing protocols does Frigate follow to qualify Ballistic Helmet Mounting Rails for field use?

Frigate performs shock, vibration, and temperature cycling tests per MIL-STD-810H procedures. Rails are subjected to 3-axis dynamic loading and accelerated life simulations. Coating durability is validated using salt spray and chemical resistance testing. These tests ensure performance under extreme operational environments.

How does Frigate address accessory retention under asymmetric loading on Ballistic Helmet Mounting Rails?

Frigate uses FEA (Finite Element Analysis) to identify high-stress regions during eccentric accessory placement. Reinforcement ribs and distributed load paths are designed to resist local deformation. Accessory locking points are positioned to minimize moment arm effects. This maintains structural rigidity even during uneven loading.

How does Frigate prevent loosening of mounted devices during long-duration missions?

Frigate integrates anti-backlash mechanisms such as spring-biased detents and elastomer pads within the rail interface. These components apply consistent retention force under mechanical cycling. Fasteners are tested for loosening torque after vibration exposure. This ensures stable accessory positioning over extended usage.

What corrosion protection methods are applied by Frigate to Ballistic Helmet Mounting Rails?

Frigate applies nano-ceramic conversion coatings followed by UV-resistant top layers for surface protection. These coatings are designed to resist salt fog, humidity, and chemical exposure. Surface conductivity is also maintained to suppress EMI interference. This approach extends rail service life in maritime and desert conditions.

Get Clarity with Our Manufacturing Insights

Best CNC Machining Solutions for High-Volume Electronics Enclosures Without Lead-Time Delays

Precision and consistency are critical in high-volume electronics enclosures. From data centers to industrial...

Scalable Manufacturing Solutions as a Competitive Advantage for Growing Enterprises

How do you manage growing production demands without sacrificing quality or breaking the bank? This is...

Sand Casting vs Investment Casting - Choosing the Right Method for Your Project

Sand casting and investment casting are valuable tools, each with its own strengths. Choosing the right...

Discover Precision with Our Metal Stamping Manufacturing Process

Metal stamping manufacturing components are essential to the automotive, aerospace, and medical industries....

From HVAC to Audio Equipment - Industrial Applications of Toroidal Transformers

Toroidal transformers are essential components in high-performance electrical and electronic systems....

Affordable Metal Stamping Components Without Compromising Quality

When thinking about affordable metal stamping, you might imagine parts in a car, the bicycle frame, or...

Overcoming Quick Turn Molding Design Challenges with Solutions

Every business is trying to get its products to market faster than its competitors. Speed in product...

Comparing Forging, Casting, and Machining for Optimal Results

How do you decide which manufacturing process is best? Do you need high-strength parts or complex shapes?...

Top CNC Machining Providers for Surface Treatment Capabilities

Component performance today is defined by more than just dimensional accuracy. Mission-critical sectors—such...

CNC Machining for Prototypes and Low-Volume Production Parts

Manufacturing high-quality prototypes and small-batch production parts is challenging. Engineers need...

We'd love to Manufacture for you!

Submit the form below and our representative will be in touch shortly.

LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

Automotive OEM & Aftermarket

Aerospace & Defense

Electronics Manufacturing

Robotics & Automation Systems

Consumer Electronics

Medical Devices

Renewable Energy

Oil & Gas Equipment

Marine & Shipbuilding