As does Lapua and some other leading bullet-makers, Barnes now uses radar to determine bullet BC values and ballistic data for its match bullets and ammunition. Barnes employs advanced Doppler Radar to record bullet speeds at multiple distances out to 1500 yards.
The Doppler radar system gathers thousands of data points as a bullet flies downrange. This radar data is used to generate a bullet specific drag curve, and then fed into a modern 6 Degree of Freedom (DOF) [ballistics software program] to generate precise firing solutions.
Determining Bullet Ballistics with Doppler Radar Data
How do you build better (more precise) ammo drop tables? With radar, that’s how. Barnes Bullets is using Doppler Radar to develop the drop tables for its Precision Match line of factory ammunition. The Doppler radar allows Barnes to determine actual velocities at hundreds of points along a bullet’s flight path. This provides a more complete view of the ballistics “behavior” of the bullet, particularly at long range. Using Doppler radar, Barnes has learned that neither the G1 nor G7 BC models are perfect. Barnes essentially builds a custom drag curve for each bullet using Doppler radar findings.
Use of Doppler Radar to Generate Trajectory Solutions
by Barnes Bullets, LLC
Typical trajectory tables are generated by measuring only two values: muzzle velocity, and either time-of-flight to a downrange target, or a second downrange velocity. Depending on the test facility where this data is gathered, that downrange target or chronograph may only be 100 to 300 yards from the muzzle. These values are used to calculate the Ballistic Coefficient (BC value) of the bullet, and the BC value is then referenced to a standardized drag curve such as G1 or G7 to generate the trajectory table.
This approach works reasonably well for the distances encountered in most hunting and target shooting conditions, but breaks down rapidly for long range work. It’s really an archaic approach based on artillery firings conducted in the late 1800s and computational techniques developed before the advent of modern computers.
There is a better approach which has been utilized by modern militaries around the world for many years to generate very precise firing solutions. Due to the sizeable investment required, it has been slow to make its way into the commercial market. This modern approach is to use a Doppler radar system to gather thousands of data points as a bullet flies downrange. This radar data is used to generate a bullet specific drag curve, and then fed into a modern 6 Degree of Freedom (DOF) [ballistics software program] to generate precise firing solutions and greatly increase first-round hit probability. (The 6 DOF software accounts for x, y, and z position along with the bullet’s pitch, yaw, and roll rates.)
Bullet-Specific Drag Curves Derived from Radar Data
Barnes’ advanced Doppler radar system can track bullets out to 1500 meters, recording the velocity and time of flight of that bullet every few feet along the flight path. The noteworthy graph below shows a Doppler Radar-derived, bullet-specific drag curve alongside the more common G1 and G7 curves:
Neither of the standard curves is a particularly good match to our test bullet. In the legacy approach to generating a downrange trajectory table, the BC value is in effect a multiplier or a fudge factor that’s used to shift the drag curve of the test bullet to try and approximate one of the standard curves. This leads to heated arguments as to which of the standardized drag curves is a better fit, or if multiple BC values should be used to better approximate the standard curve (e.g., use one BC value when the velocity is between Mach 1 and Mach 2, and a different BC value when the velocity is between Mach 2 and Mach 3.) Barnes’ approach to creating trajectory tables is to generate bullet-specific drag curves, and use that data directly in a modern, state-of-the-art, 6 DOF ballistics program called Prodas to generate the firing solution.
Story tip from EdLongrange. We welcome reader submissions.
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Hunting season is coming soon in many parts of the nation. If you’re thinking about what bullets to use for your annual game hunt, you’ll find some VERY valuable information here. Federal has created an award-winning Bullet Breakdown Video (below) that demonstrates how various hunting bullets perform in ballistic gelatin. This and other videos are found on Federal Premium Ammunition’s YouTube Channel. The Bullet Breakdown Video features four bullet types used in Federal Ammo: Nosler Ballistic Tip; Sierra GameKing; Trophy Bonded Tip; and Barnes Triple-Shock X-Bullet.
NOTE: You may want to lower the video sound level before playback.
Federal’s high-resolution, slow-motion video-graphy helps demonstrate which loads are the best for specific uses. The ultra-slo-mo footage provides a detailed view of each bullet penetrating ballistic gelatin blocks. These blocks closely mimic animal tissue and clearly display performance characteristics.
“The Bullet Breakdown Video is a great tool for hunters trying to decide on ammunition type,” said Federal’s Jason Nash. “Properly preparing for the hunt is crucial-and not all bullets are made the same. The bullet is the one link between hunter and game and can be the difference between success and failure. This video helps show hunters how different bullet construction affects terminal performance[.]” For more info, visit www.FederalPremium.com.
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Don’t have time to hand-load your own ammo, or don’t have all the equipment and dies needed? There’s a new option — something that’s actually quite revolutionary in the ammo industry. Federal is now offering custom-loaded ammunition. You choose the cartridge type and bullet type and Federal technicians put the ammo together. Think about it — this could be an interesting option for hunters who only need a few rounds a year, or if you want to try out a bullet/cartridge combo for the first time.
“Each round is painstakingly handloaded to order by our team of expert engineers in our state-of-the-art reloading workshop. Veteran craftsmen combine the best components with extra quality checks at every stage for the most consistent velocity, accuracy, and overall performance. Loads are then hand-checked for final inspection and cleaned before being custom-packed in durable, personalized packaging.”
26 Centerfire Rifle Cartridge Types + Many Bullet Options
Currently, you can choose from 26 rifle cartridge types and a wide selection of quality bullets from Barnes, Berger, Sierra, Nosler, Federal, Hornady, Swift, and more. NOTE: Federal Custom Shop ammo will be sold direct-to-consumer only. Along with rifle ammo, Federal will offer custom TSS Shotshells.
Bullet Types Offered: BARNES TIPPED TSX, BERGER HYBRID HUNTER, HORNADY ELD-X, NOSLER ACCUBOND (and Accubond LR), NOSLER PARTITION, SIERRA MATCHKING, SWIFT A-FRAME, WOODLEIGH HYDRO SOLID; and Federal TERMINAL ASCENT, TROPHY BOND BEAR CLAW, TROPHY BONDED SLEDGEHAMMER, TROPHY COPPER.
Please note: Federal Custom Shop ammunition is built to order — not pulled out of inventory in a warehouse. As such, please allow more time for processing and delivery. Typically, your Custom Shop order will take two weeks to build, plus standard delivery time. The Custom Shop handloading center is located at Federal’s main factory in Anoka, Minnesota. For more information, including how to order, what specific load options are available, and shipping details, visit: FederalPremium.com/custom-shop.html.
“If it’s not in Federal’s vast catalog as factory-loaded ammo, we may have it listed on our website as a load we will custom hand-load for you,” notes Federal Ammunition President Jason Vanderbrink. “For example, Barnes 120-grain Tipped TSX in 6.5-284 Norma and 28-gauge TSS turkey loads aren’t products we list in our catalog, but you can certainly order them through our Custom Shop.”
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NOTE: Barnes has just opened a new e-Commerce site where you can buy Barnes bullets direct from the manufacturer. To mark that development, we’re republishing an interesting article on how Barnes develops BC values and ballistic data for its match bullets and ammunition. Barnes employs advanced Doppler Radar to record bullet speeds at multiple distances out to 1500 yards.
Determining Bullet Ballistics with Doppler Radar Data
How do you build better (more precise) ammo drop tables? With radar, that’s how. Barnes Bullets is using Doppler Radar to develop the drop tables for its Precision Match line of factory ammunition. The Doppler radar allows Barnes to determine actual velocities at hundreds of points along a bullet’s flight path. This provides a more complete view of the ballistics “behavior” of the bullet, particularly at long range. Using Doppler radar, Barnes has learned that neither the G1 nor G7 BC models are perfect. Barnes essentially builds a custom drag curve for each bullet using Doppler radar findings.
Use of Doppler Radar to Generate Trajectory Solutions
by Barnes Bullets, LLC
Typical trajectory tables are generated by measuring only two values: muzzle velocity, and either time-of-flight to a downrange target, or a second downrange velocity. Depending on the test facility where this data is gathered, that downrange target or chronograph may only be 100 to 300 yards from the muzzle. These values are used to calculate the Ballistic Coefficient (BC value) of the bullet, and the BC value is then referenced to a standardized drag curve such as G1 or G7 to generate the trajectory table.
This approach works reasonably well for the distances encountered in most hunting and target shooting conditions, but breaks down rapidly for long range work. It’s really an archaic approach based on artillery firings conducted in the late 1800s and computational techniques developed before the advent of modern computers.
There is a better approach which has been utilized by modern militaries around the world for many years to generate very precise firing solutions. Due to the sizeable investment required, it has been slow to make its way into the commercial market. This modern approach is to use a Doppler radar system to gather thousands of data points as a bullet flies downrange. This radar data is used to generate a bullet specific drag curve, and then fed into a modern 6 Degree of Freedom (DOF) [ballistics software program] to generate precise firing solutions and greatly increase first-round hit probability. (The 6 DOF software accounts for x, y, and z position along with the bullet’s pitch, yaw, and roll rates.)
Bullet-Specific Drag Curves Derived from Radar Data
Barnes’ advanced Doppler radar system can track bullets out to 1500 meters, recording the velocity and time of flight of that bullet every few feet along the flight path. The noteworthy graph below shows a Doppler Radar-derived, bullet-specific drag curve alongside the more common G1 and G7 curves:
Neither of the standard curves is a particularly good match to our test bullet. In the legacy approach to generating a downrange trajectory table, the BC value is in effect a multiplier or a fudge factor that’s used to shift the drag curve of the test bullet to try and approximate one of the standard curves. This leads to heated arguments as to which of the standardized drag curves is a better fit, or if multiple BC values should be used to better approximate the standard curve (e.g., use one BC value when the velocity is between Mach 1 and Mach 2, and a different BC value when the velocity is between Mach 2 and Mach 3.) Barnes’ approach to creating trajectory tables is to generate bullet-specific drag curves, and use that data directly in a modern, state-of-the-art, 6 DOF ballistics program called Prodas to generate the firing solution.
Story tip from EdLongrange. We welcome reader submissions.
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Cutting out the middleman — that’s what Barne is doing by launching its own e-Commerce website. Yes, now you can purchase the full line of Barnes bullets directly from the manufacturer. However, Barnes ammunition will only be sold through commercial retailers — no online ammo sales.
The new e-commerce web store, Shop.barnesbullets.com, allows individual consumers the convenience of purchasing Barnes Bullets directly. This can help you find the most popular bullets that are sometimes in short supply on dealers’ shelves.
Direct Shipping for Most States
All items on the site can be shipped direct to a consumer’s residential address except certain jurisdictions (such as California), which are noted on the site. All purchasers must be of 21 years of age or older, and adult signature with photo ID will be required to verify this upon delivery. And right now Barnes is offering FREE Shipping on all orders over $99.00.
Set Up Your Own Account or Shop as Guest
Personal accounts can be created to store shipping addresses for speed of checkout, see order status, and order history. A guest checkout option is also available. After an order is submitted auto-generated emails will be sent for: order confirmation, invoice of purchase, processing status, and shipped status.
CLICK HERE to view a catalog of All Barnes products.
If you have questions about the new Barnes online store, contact Barnes Customer Service: customerservice@barnesbullets.com. Or Telephone: (435) 856-1000.
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How do you build better (more precise) ammo drop tables? With radar, that’s how. Barnes Bullets is using Doppler Radar to develop the drop tables for its new Precision Match line of factory ammunition. The Doppler radar allows Barnes to determine actual velocities at hundreds of points along a bullet’s flight path. This provides a more complete view of the ballistics “behavior” of the bullet, particularly at long range. Using Doppler radar, Barnes has learned that neither the G1 nor G7 BC models are perfect. Barnes essentially builds a custom drag curve for each bullet using Doppler radar findings.
Use of Doppler Radar to Generate Trajectory Solutions
by Barnes Bullets, LLC
Typical trajectory tables are generated by measuring only two values: muzzle velocity, and either time-of-flight to a downrange target, or a second downrange velocity. Depending on the test facility where this data is gathered, that downrange target or chronograph may only be 100 to 300 yards from the muzzle. These values are used to calculate the Ballistic Coefficient (BC value) of the bullet, and the BC value is then referenced to a standardized drag curve such as G1 or G7 to generate the trajectory table.
This approach works reasonably well for the distances encountered in most hunting and target shooting conditions, but breaks down rapidly for long range work. It’s really an archaic approach based on artillery firings conducted in the late 1800s and computational techniques developed before the advent of modern computers.
There is a better approach which has been utilized by modern militaries around the world for many years to generate very precise firing solutions. Due to the sizeable investment required, it has been slow to make its way into the commercial market. This modern approach is to use a Doppler radar system to gather thousands of data points as a bullet flies downrange. This radar data is used to generate a bullet specific drag curve, and then fed into a modern 6 Degree of Freedom (DOF) [ballistics software program] to generate precise firing solutions and greatly increase first-round hit probability. (The 6 DOF software accounts for x, y, and z position along with the bullet’s pitch, yaw, and roll rates.)
Barnes has invested heavily in this modern approach. Our Doppler radar system can track bullets out to 1500 meters, recording the velocity and time of flight of that bullet every few feet along the flight path. Consider the graph below showing a bullet specific drag curve referenced to the more common G1 and G7 curves:
Neither of the standard curves is a particularly good match to our test bullet. In the legacy approach to generating a downrange trajectory table, the BC value is in effect a multiplier or a fudge factor that’s used to shift the drag curve of the test bullet to try and approximate one of the standard curves. This leads to heated arguments as to which of the standardized drag curves is a better fit, or if multiple BC values should be used to better approximate the standard curve (e.g., use one BC value when the velocity is between Mach 1 and Mach 2, and a different BC value when the velocity is between Mach 2 and Mach 3.) Barnes’ approach to creating trajectory tables is to generate bullet-specific drag curves, and use that data directly in a modern, state-of-the-art, 6 DOF ballistics program called Prodas to generate the firing solution.
Story tip from EdLongrange. We welcome reader submissions.
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Many of our readers have been interested in learning how modern bullets are made. While a “boutique” bullet-maker, supplied with appropriate cores and jackets, can craft bullets using relatively simple hand dies and manual presses, factory production is different. The major bullet-makers, such as Barnes, employ huge, complex machines to craft their projectiles on an assembly line.
Modern hunting bullets are made with a variety of sophisticated (and expensive) machines, such as Computer Numerical Control (CNC) lathes, giant multi-stage presses, and hydraulic extruding machines that draw lead ingots into lead wire. Barnes offers an “inside look” at the bullet production process in a series of videos filmed at its Mona, UT factory. We’ve embedded four videos from the series here. These videos can also be viewed on the Barnes Bullets YouTube Channel.
Milling Slots in TSX All-Copper Bullet
This video shows how the slots (between the drive bands) in the TSX all-copper bullet are cut. The slots reduce the bearing surface that contacts the rifling. This helps reduce friction and heat, extending the life of barrels used with all-metal, drive-band bullets:
Varminator Bullets Produced in Jumbo Transfer Press
Here is the transfer press used in the production of Varminator and MPG Bullets. The process begins with a giant spool of flat copper material. The copper is stamped into jackets and eventually the formed Varminator bullets are ejected one by one into a bucket.
CNC Lathe Turns Bullets Automatically
In the video below, a Bar-Feed CNC crafts mono-bloc bullets from metal bar stock. Barnes uses a small CNC lathe to turn .50-caliber bullets from brass bar stock. We’re not sure which bullet is being made in this video. The material looks to be sintered metal. In the close-ups you can gold-colored shavings from when the machine was previously used for CNC-turned brass bullets.
Accuracy Testing in 100-yard Tunnel
Barnes regularly tests bullet samples for accuracy. In the video below, a Barnes technician loads sample rounds and tests them for accuracy in a 100-yard tunnel. The rounds are shot through a special fixture — basically a barreled action connected to parallel rods on either side. This allows the testing fixture to slide straight back on recoil (see it move back at 1:07-08 minute mark). Note how the tester actuates the trigger, which is oriented upwards, just the opposite of a normal rifle. The technician taps the upward-pointing trigger shoe lightly with a metal rod. Could this upside-down trigger orientation be useful in benchrest shooting — perhaps with railguns? It could make for an interesting experiment.
Story suggestion by EdLongrange. We welcome reader submissions.
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Sinclair Int’l now carries Bullet Sample Packs from Bullet Proof Samples LLC. These 12-bullet packs are available for Berger, Barnes, and Nosler bullets in popular weights, types, and calibers. With the sample packs, during load development, you can try out a variety of projectiles without investing in an entire box of each type. That’s smart. Sample packs range in price from $5.99 to $15.99 (for twelve bullets per pack). Most of the Berger bullet packs are priced under $10.00, with many in the $6-$7 range.
CLICK HERE for the Sinclair Int’l bullet sample pack webpage. (Once there, select Barnes, Berger, or Nosler). You’ll also find the sample packs on page six of the Sinclair Int’l print catalog. To place an order, or for additional information, call 800-717-8211 or visit www.sinclairintl.com.
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Here’s a good deal for fans of the “Terrific Twenties” — .204-caliber, low-recoil cartridges. Midsouth Shooters Supply now has Barnes 26gr “Varmint Grenade” bullets on sale. Midsouth has marked down 250-count boxes of these 26-grainers from $36.74 (reg. price) to $31.99 (sale price). The promo price works out to just $12.79 per hundred bullets. If you have a .204-Cal rifle, and are planning a prairie dog safari or ground squirrel hunt in the months ahead, you may want to grab these bullets while they’re on sale. These 26-grainers will work with 20-Cal cartridges from the .204 Ruger all the way down to the diminutive .20 Vartarg.
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Barnes Bullets has produced some videos showing the processes used to make Barnes’ popular TSX (all-copper), Match Burner (lead-core, copper jacket), and Varmint Grenade (copper jacket, powdered metal core) bullets.
Drawing Copper Wire for TSX Bullets
The first video features the TSX. These all-copper bullets start by drawing and cutting solid copper wire into slugs. The material is first drawn down to the correct diameter and then cut to the proper weight on a large industrial shear press. Great care is taken to ensure the most consistent weight possible. The machines are checked frequently. The video below show how copper wire is sized (in the first black box on the green machine) and then travels over a series of rollers to the cutting station.
Extruding Lead Wire for Bullet Cores
The second video shows the extrusion of lead core material for Barnes’ Originals and Match Burner bullets. First, soft lead is melted into 16″ long by 2 ½” round ingots. The ingots are then fed into a large steel tube and hydraulically forced through a cone at about 3500 psi, producing lead wire. This extrusion process makes the lead wire to the correct diameter. The lead wire is then fed into a cutter that chops it into the correct weight. After cutting, the lead cores are sorted and again fed into the bullet presses.
Powdered Metal Mixing for Varmint Grenade Bullets
The third video shows the mixing of metal for the composite cores in Varmint Grenade bullets. This powdered metal core is one reason why Varmint Grenades fragment so explosively on impact. The core for these bullets (identical to the MPG bullet) is made from a very fine copper and tin powder. After mixing, the metal powder matrix is fed via the hopper into the Fetta press. This machine then feeds the powder into a chamber where it is compressed into a solid core that can be put into a copper jacket. In the video, the powdered metal is fed into the machine on the left. It’s a bit difficult to see, but there is a bottom punch that matches each top punch. The two punches come together to form the core.
This is a very expensive, high-output machine. Fully tooled and set at a reasonable speed, it can make upwards of 90,000 cores per hour!
Story Tip by EdLongRange. We welcome reader story ideas.
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Bullet Proof Samples now offers 12-count packs of big-name bullets. This lets you try out many different bullet types without forking out big bucks for larger 50-ct or 100-ct boxes. Currently, Bullet Proof Samples offers projectiles from Barnes, Berger Bullets, and Nosler. The sample packs range in price from $5.49 (for 22-cal varmint bullets) to $15.99 (for a .30-Cal Barnes LRX). The Berger Bullets sample packs run $6.49 to $10.49, with the larger 7mm and 30-cal bullets at the upper end of the range. On a per-bullet cost basis, it’s still much cheaper to purchase a “normal” 100-ct box, but the sample packs let you “test before you invest.”
Berger’s Michelle Gallagher tells us: “We receive frequent feedback from shooters who are looking for bullets in small pack quantities so that they can test different bullets without the expense of buying full boxes. We’re pleased to be associated with the launch of Bullet Proof Samples. This is a new company who has done an exceptional job of addressing that concern. Bullets are packaged in blister packs, so they can be clearly seen. Each pack contains 12 bullets. They will be offering Nosler, Barnes and Berger in a variety of weights and calibers.
This effort will be featured in an upcoming issue of American Rifleman and will launch officially this week. Bullet Proof Samples is not a Berger Bullets LLC company, but we are supportive of their efforts and believe that they will be addressing a need in the shooting community that is presently unavailable.”
Story idea by EdLongrange.
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E. Arthur Brown has just started stocking Barnes Bullets. To promote this new line of projectiles, EABCO is offering “Lowest Introductory Internet Prices” on some of Barnes’ most popular bullets: Triple Shock (TSX), Tipped Triple Shock (TTSX), and Varmint Grenade. The folks at EABCO explained: “We figured the best way to launch our Barnes Bullet Line would be to offer the most popular bullets at the lowest prices. The good people at Barnes gave us a ranking by sales volume, so we picked the top 20 (and added three personal favorites), to come up with the listing you see on the right”.
Ship Up to 20 Boxes of Bullets for Just $8.00
To sweeten the deal, EABCO is offering flat-rate USPS shipping. EABCO will charge just $8.00 to ship up to 20 boxes of bullets. Mix and match bullet types and bullet brands if you want. The $8.00 shipping offer applies to Berger, Hornady, and Lapua bullets also. But you need to select “$8 Bullets Only Shipping” during check-out. If you buy a large quantity of bullets, you can save a bundle with that shipping offer.
Qualities of Barnes Bullets
TSX bullets are widely known for their accuracy, consistent expansion on impact, and solid, weight retention. The “Triple Shock” name refers to the three grooves formed into the bearing surface. The Tipped Triple Shock is an enhanced-BC version of the Triple Shock with a polymer tip instead. Barnes claims that the higher BC of the TTSX tipped bullets provides a flatter trajectory for long-range shots. The popular lead-free Varmint Grenade bullets combine a composite (lead/tin) frangible core with a hollow cavity and copper jacket. These are designed to virtually disintegrate inside predators, minimizing pelt damage. Watch the video below for a dramatic demonstration of how Varmint Grenades perform when launched a very high velocities.
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This approach works reasonably well for the distances encountered in most hunting and target shooting conditions, but breaks down rapidly for long range work. It’s really an archaic approach based on artillery firings conducted in the late 1800s and computational techniques developed before the advent of modern computers.
Federal’s high-resolution, slow-motion video-graphy helps demonstrate which loads are the best for specific uses. The ultra-slo-mo footage provides a detailed view of each bullet penetrating ballistic gelatin blocks. These blocks closely mimic animal tissue and clearly display performance characteristics.
This approach works reasonably well for the distances encountered in most hunting and target shooting conditions, but breaks down rapidly for long range work. It’s really an archaic approach based on artillery firings conducted in the late 1800s and computational techniques developed before the advent of modern computers.
Many of our readers have been interested in learning how modern bullets are made. While a “boutique” bullet-maker, supplied with appropriate cores and jackets, can craft bullets using relatively simple hand dies and manual presses, factory production is different. The major bullet-makers, such as 
Barnes Bullets has produced some videos showing the processes used to make Barnes’ popular TSX (all-copper), Match Burner (lead-core, copper jacket), and Varmint Grenade (copper jacket, powdered metal core) bullets.
Berger’s Michelle Gallagher tells us: “We receive frequent feedback from shooters who are looking for bullets in small pack quantities so that they can test different bullets without the expense of buying full boxes. We’re pleased to be associated with the launch of Bullet Proof Samples. This is a new company who has done an exceptional job of addressing that concern. Bullets are packaged in blister packs, so they can be clearly seen. Each pack contains 12 bullets. They will be offering Nosler, Barnes and Berger in a variety of weights and calibers.
