PolyCase Projectiles


For over a century most bullets have been mass-produced with a process called cold forming. Lead and copper were shaped with brute force in punches and dies to create projectiles. While this is still an effective way to produce projectiles, other manufacturing methods have progressed thus giving us new ways to produce bullets.

PolyCase Ammunition has redefined the bullet manufacturing process by applying advanced injection molding technology, cutting edge engineering and a highly specialized metal-polymer compound to designs and a process that results in precise, consistent, accurate, low ricochet, range compliant bullets with sound terminal performance. Our organic tool-making capability and flexible manufacturing process allow us a great deal of agility in terms of rapid prototyping and bullet production, with the ability to meet very specific performance characteristics on very tight timelines. The process allows us to go from concept to full production in greatly reduced time compared to swagging (faster time-to-market) and results in precision bullet designs that function very well in modern firearms.

These revolutionary bullets are available in the brass-cased Ruger® and Inceptor® brands of ammunition.


Powdered metal has been around for decades, but blending powdered metal with polymers and injection molding precise parts is a fairly modern process.  The proprietary copper-polymer compound used in PolyCase bullets is developed with reclaiming the valuable copper in mind. While processes like sintered metal bullets and pressure-formed shotgun pellets have become commonplace, PolyCase is the first company in the U.S. to produce a completely injection molded metal-polymer bullet incorporating designs for increased terminal performance.  With extensive testing and evaluation, our bullets deliver consistent and predictable results – at a price point that makes them competitive with conventional lead core bullets.

Efficient Manufacturing

PolyCase projectile manufacturing processes do not yield byproducts that turn into potentially hazardous waste streams. And, because there is no final cleaning or polishing of the parts when they come out of the machine, the ammunition manufacturing process becomes remarkably streamlined.  The raw materials we can use to create bullets are almost as limitless as your budget allows.

Predictable Performance

The standard PolyCase RNP™ (Round Nose Precision) and TNP™ (Truncated Nose Precision) projectiles deliver predictable performance on the range – but that doesn’t mean they’re boring. There is no pre-fragmenting or breaking in the barrel which could result in stray projectiles traveling in unintended directions. On hardened targets like steel plates, our bullets simply turn back into very small fragments…resulting in a drastically reduced chance of ricochet. On soft targets, like 10% ballistic ordnance gelatin, the PolyCase bullet stays together, penetrates reliably and retains its weight.


Our standard bullet is constructed of a polymer-powdered metal compound that delivers bullet weights on the lower end of the spectrum when compared to current frangible bullet offerings. These weights maintain enough resistance to deliver consistent firearm function while using conventional propellants.

To the shooter, less weight means less recoil, higher velocity and flatter trajectories. Firearms like compact 380 Auto and 40 S&W’s are typically unwieldy to shoot, but with a switch to a lighter bullet, recoil is reduced.  The lighter weight makes it easier for beginner and smaller-statured shooters to handle these handguns, thus making for a more enjoyable range sessions.


Another of the major benefits of PolyCase bullets is higher velocities.  A higher bullet velocity results in a flatter flight trajectory.  Along with sound bullet design, this equates to hitting targets at the point of aim (greater precision).  Greater velocity also helps cut down on ricochets by turning PolyCase ammunition back into recyclable fragments after they strike a steel plate (or baffle) in an indoor range.


Historically, bullets relied on frontal expansion to transfer energy to a target. PolyCase is taking a different approach to transfer energy from bullet to target. We’ve developed the first of numerous patent-pending frontal profiles designed to not expand or fragment in the transfer of energy.  Instead, the ARX® bullet uses much higher velocities, rotation and the constricting characteristics of the flutes incorporated into the design to increase the density of fluid passing through the ARX® flutes to transfer kinetic energy from bullet to soft tissue. With our manufacturing process, asymmetrical shapes are easily produced at a fraction of the cost of machining.