I have some less lethal launchers from Umarex (HDR 68 and HDB 68) and a Byrna LE. All my Umarex launchers are tuned. When I got them, I started testing kinetic projectiles to find the best performance. I bought a chronograph and built a penetration tester. I tested projectiles weighing 3g, 4.5g, 7.3g, 7.7g, 9.9g, 12g, and 20g, as well as solid and shaped rounds. Using my tests and math, I figured out 8.4g rounds give the best penetration and work well with a wide range of launchers. I had custom 8.4g rounds made, tested them, and they performed amazing. I even started a company and called them ‘The Smasher’ from Less Lethal Ballistics. I’d love feedback on this to improve and refine the idea. Let me know what you think!
Are the 8.4g rounds also the best fit for the barrel bore? Bore matching can help a lot by reducing air blow-by.
Brett said:
Are the 8.4g rounds also the best fit for the barrel bore? Bore matching can help a lot by reducing air blow-by.
The diameter is 17.27 mm +/- 0.025 mm. I measured it using a precise digital caliper, taking data from hundreds of projectiles.
@Paxton
What about the diameters of the other projectiles you tested?
Brett said:
@Paxton
What about the diameters of the other projectiles you tested?
I chose a diameter close to 0.68 inches and invested a lot in molds to ensure minimal variation during manufacturing.
@Paxton
I meant the other weights you tested, not the ones you made.
Brett said:
@Paxton
I meant the other weights you tested, not the ones you made.
I tested about 20 manufacturers’ balls and measured hundreds of them. Most are between 0.68 and 0.683 inches. My diameter was chosen to fit the most launchers while keeping mass as the top priority for penetration.
@Paxton
Got it. My point is: could the success of the 8.4g round in your tests be due to its better bore match rather than just its weight? For example, I’ve had heavier rounds around 10g perform better due to bore match, even with more mass.
@Brett
Good question. Yes, weight and diameter both matter. My tests showed penetration forms a curve—too light or too heavy reduces it. The peak was at 8.4g. I designed a steel core coated with polyethylene for precise weight. After testing prototypes, they performed better than lighter or heavier rounds with the same diameter.
@Paxton
When you say penetration, what were you testing on and from what distance? Did energy readings match the penetration results?
Brett said:
@Paxton
When you say penetration, what were you testing on and from what distance? Did energy readings match the penetration results?
I built a penetration tester with vertical cardboard sheets spaced apart. Tests were done at 5 meters, as it’s a realistic home defense distance. I recorded muzzle velocity with a chronograph. My key finding was that optimal weight mattered more than the launcher’s power. Here’s a video of my tester: https://youtu.be/aXlmVoM_ZqE?feature=shared
Brett said:
@Paxton
What about the diameters of the other projectiles you tested?
I gathered a huge amount of data across my tests.
So are you basically turning a paintball gun into a home defense tool by swapping paintballs with solid rounds? Is the goal to deter or injure an intruder with blunt impact?
Blake said:
So are you basically turning a paintball gun into a home defense tool by swapping paintballs with solid rounds? Is the goal to deter or injure an intruder with blunt impact?
Yes, I’m optimizing launchers for maximum performance. Standard paintballs are under 3.2g and 200 fps for safety. Companies like Byrna and Grimburg make higher-power less-lethal launchers. My 8.4g Smasher projectiles improve stopping power while remaining legal in all 50 states. Any launcher can get a boost with these rounds. See more here: https://lesslethalballistics.com
@Paxton
Thanks. What exactly are you measuring penetration into?
Blake said:
@Paxton
Thanks. What exactly are you measuring penetration into?
I’ve designed the Smasher to be effective and 100% legal. It can definitely drive off an intruder.
Blake said:
@Paxton
Thanks. What exactly are you measuring penetration into?
I’ve designed the Smasher to be effective and 100% legal. It can definitely drive off an intruder.
Has anyone tested lethal self-defense cases with these in court yet?
@Blake
The Smasher is powerful but less damaging than a subsonic .22LR. I’m maximizing CO2’s potential while staying within legal limits. Hopefully, courts don’t take away non-lethal self-defense options. Why should we need permits for basic protection? Will rocks need permits next?
@Paxton
Why not just get a gun then? What’s the motivation for this instead?
Blake said:
@Paxton
Why not just get a gun then? What’s the motivation for this instead?
Gun permits are a hassle in many states. CO2 launchers are legal without permits nationwide and can be ordered online. Plus, they’re less lethal than firearms and more humane. It’s a great way to defend your home without government interference.