Radical Defense expands 3D-printed range of blast mitigation systems

Radical Defense's Blast Attenuation Device – M2 for .50 calibre machine guns. (Radical Defense)

US defence company Radical Defense showcased new blast mitigation solutions at the Defence and Security Equipment International (DSEI) 2025 exhibition, including the Blast Attenuation Device – M2 (BAD-M2) Direct Thread suppressor.

Radical Defense has collaborated with weapons suppliers to develop a range of ballistic suppressors and blast mitigation devices for weapon calibres from 5.56×45 mm up to 30 mm, with work continuing for larger calibres up to 155 mm. By using additive manufacturing capabilities (a form of 3D printing), Radical Defense told Janes it has manufactured suppressor products with structural architectures which could not be replicated with conventional computer numerical control (CNC) machining technology. The focus on adopting an additive manufacturing-based supply chain, enabled by 3D printers supplied by UK-based company Renishaw, is intended to improve cost-efficiency and scaleable manufacturing across the firm's entire portfolio of suppressor products.

The BAD-M2 was designed for integration with the M2A1 and FN M2HB-QCB .50 calibre machine guns in service with a variety of armed services globally. Requiring no permanent modifications to the host weapon, the BAD-M2 integrates a flash hider within a monolithic, corrosion-resistant body covered in a proprietary infrared (IR)-suppressive, non-reflective coating, designed to reduce visual and IR spectrum signature.

Radical Defense has been directly contracted by the US Navy's Naval Air Systems Command (NAVAIR) Direct and Time Sensitive Strike (PMA-242) programme to develop a solution for FN Herstal's FN M3M machine gun, a system currently in operation on various rotary-wing platforms of the US Navy, Marine Corps, and Air Force.