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Defence company HighCom Limited has celebrated the successful recommissioning of its ultra-high isostatic pressure consolidation technology in the United States.
HighCom’s XTclave system is used for advanced composite manufacturing and the system was successfully relocated from Australia to its manufacturing facility in Columbus, Ohio, in the first quarter of 2024.
The system is designed to produce ultra-lightweight, thin and high-strength ballistic products suited for employment by military personnel, government agencies and specialised law enforcement units.
With the system now fully operational, HighCom is reportedly focusing on completing training for US-based personnel and finalising the integration of ancillary equipment to support optimised functionality and production efficiency.
“The successful recommissioning signifies the completion of an 18-month strategic endeavour, establishing a robust foundation for the company to initiate production of a new generation of globally competitive and highly sought-after products while enhancing operational efficiencies and contributing to improved product margins,” HighCom said in an ASX announcement.
“As part of the reassembly process, significant enhancements were implemented, including the integration of a new water-based cooling system, which replaced the previous air-based system, to ensure optimal performance under Ohio’s climate conditions.
“Additionally, a larger pressure vessel was constructed, doubling the original capacity and achieving certification from the American Society of Mechanical Engineers.
“This upgraded vessel enables the XTclave to complete a minimum of three production cycles per shift, with an estimated annual output of up to 40,000 ballistic plates.”
In addition, the company has advised that the expanded capacity and versatility of the new pressure vessel could allow processing of other products such as ballistic plates, helmets, shields, complex geometries and specialised applications such as aviation and vehicle armour.
Simultaneously, HighCom has confirmed it will recommence production of select XTclave product lines previously manufactured in Adelaide, South Australia, for commercial availability in the first quarter of fiscal year 2026 (Q1 FY2025–26).
“We are proud to announce the successful recommissioning of our proprietary XTclave system at HighCom’s Columbus, Ohio, facility,” HighCom chief executive officer Todd Ashurst said.
“This milestone marks a significant step forward in our commitment to innovation, operational excellence and delivering world-class ballistic protection solutions.”
“This achievement is more than a technical upgrade; it is a strategic enabler.
“It allows us to accelerate the development of next-generation ballistic products, strengthen our collaboration with the US Department of Defense and pursue major contract opportunities through Berry Amendment compliant manufacturing.
“Thank you to our dedicated team who made this possible. We are excited about the future and confident that XTclave will play a pivotal role in HighCom’s continued growth and leadership in advanced armour solutions.”
