The US Army Combat Capabilities Development Command (DEVCOM) Armament Center has rolled out a new packaging system, marking the first major overhaul of small-caliber ammunition packaging since World War II.
Called SixPAC, the system consists of two lightweight polymer ammunition containers in a steel outer pack and can accommodate 6.8mm cartridges.
These combinations simplify transport, streamline manufacturing, reduce weight, and shrink the overall logistical footprint by fitting more containers and ammunition onto each pallet.
The defining feature is the elimination of the wooden outer box, which required manual assembly, could be susceptible to mold, and often needed remediation.
By moving away from traditional packaging, it reduces the need for chemical preservatives while limiting environmental impacts and supply-chain vulnerabilities.
Shaped by Soldier’s Feedback
US soldiers tested SixPAC throughout 2024 and 2025, with their positive feedback guiding further evaluation and refinement.
Several personnel highlighted the importance of weight savings aboard aircraft and watercraft, noting that the lighter system could increase the amount of ammunition they carry.
Multiple designs are under development, with the tactical polymer inner containers expected to weigh roughly half as much as legacy steel versions.
“It’s a developing field, and polymers are unique — you can modify them, including additives that improve impact performance, stiffness, or dimensional stability,” said Edward Lucas, a mechanical engineer and polymer designer at the Armament Center.
“You can add more ingredients to the cauldron, and your potion will come out different, trading some characteristics for others.”
