The Cougar is a mine-resistant ambush-protected (MRAP) and infantry mobility vehicle structured to be resistant to landmines and improvised munitions.

It is a family of armored vehicles produced by Force Protection Inc, which manufactures ballistic and mine-protected vehicles. The vehicles are integrated by Spartan Motors. These vehicles are protected against small arms, land mines and improvised explosive devices (IEDs) using a combination of design features and materials to protect both the crew and engine compartment against a wide range of attacks. A monocoque type, V-shaped hull extends to the engine bay and serves to direct the blast away from under the vehicle. The dual air-conditioners help keep heavily dressed troops from overheating in temperatures over 100 °F (38 °C) in Iraq.

Force Protection, Inc. was formed in 2002 when Sonic Jet purchased Technical Solutions Group, using the name Sonic Jet until 2004. Technical Solutions Group had been a defense company in the US that was involved in a range of products, including mine-resistant vehicles based on South African designs. Two vehicles were sold to the US Army for evaluation which were used for ordnance clearance on Army ranges, and eight heavily protected vehicles, called Tempest, were sold to the British Army in 2001; these were fitted with an extra ceramic armored bellyplate for protection against Yugoslav TMRP-6 "tank-killer" mines intended to attack the center of a vehicle.

In early 2004 the United States Marine Corps (USMC) visited Force Protection and, having seen a photo-montage of a new design of MRAP on a company brochure, asked if it could be produced and delivered within 6 months of an order for operations in Iraq. The photo was a still only concept image, but a senior person in the company offered to design, develop and build a new vehicle, that met the USMC requirement, within the deadline of 6 months. This was achieved in spite of limited funds and having to set up and train personnel in military-type projects. The package handed over to the USMC in October 2004 also included an initial set of spares and technical publications. Given that most defence companies quote at least ten years to develop a new vehicle, to have achieved this in some five and a half months was extraordinary.

The new design differed in many respects from the earlier South African vehicles, although in order to provide a degree of continuity for government contracting reasons, it retained the name "Cougar" given to two earlier GMC-powered vehicles sold to the US Army. The new Cougar had a single hull bottom-plate that ran the whole length of the vehicle, and this formed the basis of the protection of both the crew compartment and the engine-bay. It made for a much stiffer hull, with fewer welds, adding to the overall level of blast-protection. The structure of the hull around the commander and driver was considerably strengthened to add to the torsional stiffness of the vehicle, and the hull-sides were redesigned to provide additional space for troops or equipment. A full armor-upgrade pack was offered from the start, and the design specifically allowed for the addition of advanced armor systems such as the British chobham type.

Growth potential was limited in many of the South African designs, and this was addressed from the outset in the new Cougar. Heavier axles and a more powerful engine and transmission were selected, all of which were already in use in the US and other forces that were thought to be likely users of the Cougar. Logistic support was a major design requirement, and the components chosen were carefully assessed for the level of support that their respective original equipment manufacturers could provide.

Above all, the new design was developed under the auspices of first-world defence standards such as the United States Military Standard and the UK's Defstans, both of which also conformed with NATO STANAGs. This required, amongst other things, that a full product safety-case be developed and maintained from the outset, as well as appropriate training needs analysis and spares predictions. This meant that the new Cougar was capable of being fully operational in a wide range of climatic conditions by fully-equipped and clothed NATO troops, based upon a 95-percentile NATO crewman.

The initial USMC requirement, based upon first meetings with Force Protection VPs, was written on half a page of foolscap. After further talks, the need for levels of mobility covering beach-operations resulted in a suggestion that the 4x4 design should be augmented by a 6x6 version, which would also have a larger payload and volume in the cargo area. It was this version that led to increased US Army interest, as they had a need for a vehicle to carry a large explosive ordnance disposal robot. Subsequent meetings with the Army also led to changes in some of the major sub-systems to ensure even greater commonality with in-service equipment in order to ease training and support.