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LSAT light machine gun
LSAT light machine gun
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The LSAT light machine gun is a component of the Lightweight Small Arms Technologies (LSAT) program. The purpose of the program was to develop a lighter, yet highly reliable light machine gun (LMG). The program was initiated in 2004, when the Joint Service Small Arms Program (JSSAP) challenged the American defence industry to develop a lighter small arms and also design lighter ammunition.[1][5][6]

Key Information

The LMG provides a major reduction in weight over legacy weapons, as well as improvements in other areas, such as controllability and reliability.[2] As of 2008, it had two configurations, one that fires cased telescoped ammunition, and one that fires caseless ammunition.[2] After further research and development into both technologies and the guns that fire them, one of the two variants was to be chosen for production.[1] By May 2015, 85,000 cased-telescoped rounds had been fired through 10 test weapons, with testers claiming the weapon had gone as far as it can go until the Army decides if it wants to make it a Program of Record.[7]

History

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LSAT concept image

Development began with the two types of weight-reducing ammunition, and a light machine gun to serve as a testbed and technology demonstrator.[2] Use of an LMG for this purpose is notable, considering its greater technical complexity than infantry rifles. The use of advanced computer simulations to accelerate development may have mitigated this. For development, the use of extensive computer simulation and modelling reduces both time and expenditure for prototyping and testing. The program also uses a 'spiral development' approach, whereby the weapon and ammunition is rolled out in stages or 'spirals', each stage producing a new version that is an improvement on those from previous spirals. A competition down-selected the design concepts of various companies to leave an AAI Corporation-led team of companies as the developers of the weapon system. The cohesive team of companies is combined with government support to ensure success. The parallel development of the two ammunition types meant that, if the caseless ammunition effort succeeded, much of the development work gained with the composite cased weapon could be applied to it, and, if it failed, the composite-cased version was likely to succeed on its own.

Design

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LSAT without magazine, mock fire for the first time by Picatinny Senior Commander and PEO Ammunition Brig. Gen. Jonathan A. Maddux at Picatinny Arsenal

The LMGs built made a 44% and 43% reduction of weight (for the cased telescoped and the caseless weapons, respectively). Secondary goals have also been met: the LMG has the potential to improve battlefield effectiveness (due to its simpler and more consistent weapon action, its light weight and low recoil, and its stiffer barrel); its use of recoil compensation (with a long-stroke gas-system, for example) has produced positive feedback regarding controllability; the simpler mechanism of the LMG is both more reliable and easier to maintain; a rounds counter has been integrated to improve maintainability, and the weapon is capable of accepting other electronic devices; improved materials used in the chamber and barrel have reduced heat load on the weapon; and the weapon cost is equivalent to the existing M249. The standard LSAT machine gun weighs 9.4 lb empty, compared to 17.6 lb for a standard SAW. Cased telescoped ammunition weighs 40% less than brass-cased ammo, so a 100-round ammunition belt weighs about 2 lb for the LSAT, compared to 3.3 lb for a brass-cased belt.[8]

A soldier engages a close range target with the light machine gun during a military unit assessment at Fort Benning, Ga.

The LMG design is a traditionally laid-out machine-gun. It has several features conducive to its use as a light machine gun, such as a quick-change barrel, a vented handguard, a belt feeding mechanism, provisions for the use of an ammunition pouch, and a rate of fire of approximately 600 RPM. Other features include its light weight, an ammunition counter, and a highly stiff and heat resistant barrel achieved with the use of fluting and specialized alloys.[1][9] When firing, the weapon's chamber swings around a longitudinal pivot; it swings from horizontally parallel with the pivot (the firing position) to vertically parallel (the feed position), and back again.[10] A long-stroke gas-piston is used to operate this action. A round is fed into the chamber at the feed position using a rammer, and the new round also serves to push a spent or dud round out of the far end of the chamber. Such rounds are pushed forward, parallel to the barrel, and they slide into a separate mechanism that ejects them out of one side of the gun. The advantages of this whole action include its simplicity, its isolation of the chamber from barrel heat, and its positive control of round movement from extraction to ejection. In the caseless firing version of the weapon, another mechanism is introduced to seal the chamber during firing, accounting for the slightly increased weight of the caseless version.

Testing

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In September 2011, 19 soldiers participated in a two-week assessment of the LSAT light machine gun at Fort Benning, Georgia to demonstrate its capabilities against the M249 SAW. In one test the soldiers, half armed with SAWs and half with LSATs, marched six miles in full combat gear then fired at targets to measure stress and muscle fatigue. Another test had the soldiers sprint 200 yards wearing body armor and a basic load of ammunition, then rapidly engage close-range targets. A third week involved soldiers of the 75th Ranger Regiment performing a squad maneuver live-fire exercise in an urban setting. Feedback from participants favored the LSAT for its lighter weight and decreased recoil. Soldiers remarked the LSAT had better accuracy than the M249. The semi-automatic option made it more viable for room clearing. One Ranger even said the LSAT performed better than the Mk 46 machine gun used by special operations forces.[11] 15 out of 19 soldiers that participated in the assessment said they would prefer using the LSAT in combat rather than the SAW. The LSAT LMG is 41 percent lighter than the 21.5 lb (9.8 kg) SAW and its ammunition volume is 12 percent less, enabling all the soldiers that maneuvered the woodland obstacle course to complete it faster when carrying it. Participants also took less time to zero their machine guns when using the LSAT; one soldier failed repeatedly to accurately zero the SAW but successfully zeroed the LSAT on the first try. The LMG users completed the course, on average, one minute and 11 seconds faster than SAW users due to increased mobility given by its shorter length, adjustable stock, and lighter ammo. When firing, gunners felt virtually no recoil from the LSAT LMG.[12] The eight prototype weapons fired a combined 25,000 rounds, moving its cased telescoped ammunition to technology readiness level 7.[8]

The LSAT light machine gun was assessed in the Army's Dismounted Non-Networked Experiment (DNNE) in August 2013 at Fort Benning.[13] It was among several items showcased at an event at Fort Benning through 24 September 2013 featuring the Army's latest individual and squad kit developments.[14] Seven LSAT LMGs and 9,700 rounds were provided to three rifle squads and one weapon squad at a series of range events. They increased lethality at all ranges with faster speed of engagement and better shot placement, increased the gunner's mobility due to its reduced size and weight, and led to more precision fires in standing and kneeling positions.[15]

Future improvements

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The designers project further improvements. These include improved projectile technologies such as environmentally friendly bullets and a change in bullet size in order to increase combat effectiveness,[1] as well as the integration of electronics such as ammunition count readouts, lasers, optical sights, rangefinders, and bullet drop compensation.[4] The Army is pursuing cased telescoped ammunition. This development is far along, and they say a new LMG is fielded in 2022 with unequivocal support. The Marine Corps is pursuing caseless ammunition, which is less developed and will take several more years to refine.[16] A compact version is also being developed with a 4-inch shorter barrel and folding, telescoping buttstock.[3] The 5.56 mm LSAT machine gun has been renamed the Cased Telescoped Light Machine Gun (CT LMG).[17]

On 14 May 2014, Textron Systems was awarded a two-year $5.7 million contract for work that included development of 7.62 NATO cased-telescoped ammunition and an operating mechanism to incorporate into the LSAT machine gun to create a lightweight 7.62 mm version.[18][19] Textron unveiled their 7.62 mm cased-telescoped machine gun design at the 2015 Special Operations Forces Industry Conference. It weighs 14.5 lb (6.6 kg), almost 8 lb (3.6 kg) lighter than the 22 lb (10.0 kg) M240L and much lighter than the 27 lb (12 kg) M240B. A firing prototype is expected to be ready by fall 2016.[7]

2016 developments

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During 2016 the LSAT program advanced the 7.62mm LMG to TRL 7, with range testing. It also finished development on the 6.5mm derivative of the 7.62mm CT cartridge and tested that as well.[20] The program had by the end of 2016 demonstrated the target weight savings and moved on to more capable longer range 6.5mm ammunition. [21]

2018 developments

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In July 2018, the US Army announced a new, different program to develop a replacement for the M249 light machine gun, with six companies, including Textron, competing to develop the Next Generation Squad Weapon Program (NGSW), replacing the SAW, as well as develop ammunition for it that is at least 20% lighter.[22]

Physical requirements stated a target of 12 lbs (5.44 Kg) and 35 inches (890 mm) of length using an Army-desired 6.8mm bullet. The NGSW-AR contracts awarded July 2018 include prototypes and ammunition which would be delivered for Army evaluation in June 2019. Both NGSW-R and NGSW-AR prototypes were to be eventually tested. The NGSW program effectively replaced the LSAT program.[22][23]

2024 developments

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As of 2024 Textron has lost the NGSW contract and the M249 will be replaced by the XM250.[24]

See also

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References

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Revisions and contributorsEdit on WikipediaRead on Wikipedia
from Grokipedia
The LSAT light machine gun (LMG) is an experimental developed by the U.S. Army as part of the (LSAT) program, initiated in 2004 to create lighter small arms and ammunition that reduce soldier combat loads by approximately 40% without compromising lethality or reliability. It features a gas-operated, belt-fed design firing cased telescoped (CT) ammunition encased in rather than traditional , enabling an empty weight of about 9.4 pounds—roughly half that of the M249 SAW it aimed to replace—and a full 1,000-round combat load weighing 20.4 pounds less than conventional equivalents. The weapon operates from an with a long-stroke and rotating chamber mechanism for controlled , achieving a cyclic around 650 rounds per minute while supporting both semi-automatic and fully automatic modes. Originally led by AAI Corporation under the Army's Armament Research, Development and Engineering Center (ARDEC) at Picatinny Arsenal, the LSAT LMG progressed from concept to functional prototypes within six years, with initial development focusing on both caseless and CT variants before prioritizing the latter for its balance of performance and manufacturability. By 2011, Textron Systems had acquired AAI and continued refinement, producing eight prototypes that underwent extensive testing, including live-fire demonstrations at Marine Corps Base Quantico and a two-week military utility assessment at Aberdeen Proving Ground involving nearly 20 soldiers conducting combat drills, marches, and over 25,000 rounds fired. Testers reported improved mobility, accuracy, and agility with the LMG, completing maneuver courses up to 71 seconds faster than with the M249, though challenges like ammunition sensitivity to environmental factors were noted. Although the LSAT program did not result in direct fielding by —due to shifting priorities toward broader caliber and technology evaluations—its innovations in polymer-cased and lightweight designs directly influenced the U.S. Army's (NGSW) program launched in 2017, where submitted a 6.8mm CT-based LMG derived from LSAT technology. This legacy contributed to advancements in modern automatic weapons, even as the Army selected SIG Sauer's hybrid-cased XM250 in 2022 as the NGSW successor to the M249.

Background and Development

Program Origins

The LSAT (Lightweight Small Arms Technologies) program was initiated in 2004 by the (JSSAP), a collaborative effort under the U.S. Army's Armament Research, Development and Engineering Command (ARDEC). This program aimed to advance U.S. military modernization by addressing key limitations in existing squad support weapons. The primary objective of the LSAT program was to develop a light machine gun that achieved a 40% weight reduction compared to the M249 Squad Automatic Weapon, while preserving or enhancing reliability, lethality, and controllability. This focus stemmed from post-2003 Iraq War operational experiences, where lessons learned highlighted the need to alleviate excessive soldier loads—often exceeding 79 pounds for automatic riflemen in urban and dismounted infantry roles—to improve mobility and endurance. Initial funding supported feasibility studies on lightweight materials and , with JSSAP allocating resources starting in fiscal year 2004 to explore these innovations. The program also considered compatibility with the initiative to align with broader soldier system enhancements.

Prototyping and Contractors

The (LSAT) program designated as the lead developer for the (LMG) component starting in 2004, with AAI being acquired by Systems in 2007, continuing oversight through 2017. served as a key subcontractor, contributing to propellant characterization and integration efforts. Initial prototypes of the LSAT LMG were completed in 2010, incorporating polymer-cased designed to achieve significant weight reductions compared to traditional brass-cased rounds, aligning with the program's overarching goal of lightening soldier loads. These early models featured an open-bolt, gas-operated mechanism using a long-stroke , which presented engineering challenges in balancing reliable cycling with minimized recoil impulses to maintain controllability during sustained fire. The initial prototypes weighed approximately 9.8 pounds empty, representing a substantial decrease from the baseline M249 . By 2011, the program had produced several prototypes for both caseless (CL) and cased telescoped (CT) variants, including at least 8 CT LMGs available for military utility assessments, enabling comprehensive reliability and endurance testing under various conditions. A key milestone occurred in 2010 with a demonstration at , where prototypes exhibited a cyclic rate of approximately 650 rounds per minute in both semi-automatic and full-automatic modes, highlighting progress in weapon action integration.

Design Features

Weapon Mechanism and Specifications

The LSAT light machine gun employs a gas-operated, open-bolt mechanism utilizing a long-stroke located below the barrel, which drives an oscillating rotating chamber to facilitate push-through feeding and ejection for reliable operation with belted . This design incorporates a quick-change barrel system to support sustained fire without overheating, while the long-stroke contributes to a soft impulse that enhances controllability during automatic fire. The weapon supports belt-fed configurations typically accommodating 100- to 200-round belts, with provisions for selectable semi-automatic and fully automatic modes in its prototypes. Key physical specifications include an overall length of 36.1 inches with the stock retracted and a standard barrel length of 16.3 inches, enabling maneuverability in squad-level engagements. The empty weight is 9.8 pounds for the cased telescoped (CT) variant and 9.9 pounds for the caseless (CL) version, representing a 44% reduction compared to the M249 SAW's 17.6 pounds and achieved through the use of lightweight materials in the receiver and components. The cyclic is approximately 650 rounds per minute, balanced for effective while minimizing ammunition consumption. Ergonomic features prioritize user comfort and modularity, including an adjustable bipod for stability, a collapsible buttstock for compact storage, and multiple Picatinny rails for mounting and accessories. A muzzle compensator and internal buffer system further mitigate , allowing for improved accuracy in prolonged bursts.

Ammunition Innovations

The LSAT program's ammunition innovations centered on two primary formats: cased telescoped (CT) and caseless (CL), both designed to dramatically reduce the and volume of 5.56×45mm NATO-compatible rounds while preserving ballistic performance. The CT rounds featured a lightweight cylindrical case encasing a telescoped fully embedded within a consolidated charge, eliminating the traditional case and enabling a 40% reduction compared to standard M855 . This construction, combined with high-ignition-temperature , allowed for a 12% volume reduction as well, facilitating higher capacity in belts or magazines without increasing soldier load. For example, a 1,000-round load of CT weighs 21.7 pounds compared to 33.8 pounds for conventional M855 linked , enabling 55% more to be transported at the same . The CL variant took this further by eliminating the case entirely, with the projectile directly molded into a solid block using an HMX-based energetic binder such as , resulting in approximately 50% weight savings and 40% volume reduction over brass-cased equivalents. Each CL round weighed about 6.3 grams versus 12.2 grams for the M855, allowing a 600-round package to weigh just 10.1 pounds compared to 20.8 pounds for standard linked ammunition. Ballistically, both CT and CL rounds achieved muzzle velocities around 3,020 feet per second, matching the M855's performance for comparable penetration and against soft targets at typical engagement ranges. Additionally, the telescoped design contributed to tighter shot dispersion, with preliminary tests showing improved accuracy over legacy 5.56mm rounds in full-automatic fire. Development of these rounds addressed key challenges inherent to their novel compositions. For CT ammunition, optimizing the case's durability and attachment of the endcap to the proved critical, alongside ensuring reliable ignition across extreme temperatures from -65°F to +145°F, with over 4,000 rounds tested successfully by 2007. The CL format faced greater hurdles, including higher heat generation due to the lack of a metallic case to act as a , leading to potential risks after sustained fire, though mitigated in designs with no incidents after 300 rounds at 200°F. Sealing the caseless block against moisture and required advanced water-resistant hardening treatments, while residue buildup and chamber wear from the burning demanded iterative refinements to maintain reliability. Production scalability emerged as a significant , particularly for transitioning from prototypes to mass manufacture. By , a pilot facility at MAST could produce 4,000 to 5,000 rounds per day for CT and CL variants, with plans to scale to 20,000 rounds for 7 validation and 100,000 for military utility assessments targeted around 2013. Initial efforts focused exclusively on 5.56mm calibers, integrated into belt-fed systems supporting up to 200-round loads for the configuration, though challenges in link durability and cost efficiency persisted for full adoption. These innovations briefly integrated with the weapon's push-through feeding mechanism to enable reliable operation without traditional extraction.

Testing and Evaluation

Early Field Trials

The early field trials of the LSAT light machine gun, conducted between 2010 and 2013, focused on evaluating its performance in controlled environments to assess reductions in weight, ammunition requirements, and improvements in accuracy and reliability compared to the baseline M249 SAW. Initial testing emphasized the weapon's cased telescoped (CT) and caseless (CL) ammunition variants, with procedures incorporating live-fire demonstrations and simulated combat scenarios to measure operational impacts. These trials were overseen by the U.S. Army's Armament Research, Development and Engineering Center at , building on the program's goal of enhancing infantryman mobility without sacrificing lethality. In June 2011, a live-fire demonstration was held at , , where soldiers and U.S. Army civilians test-fired prototype LSAT LMGs to evaluate basic handling and ballistic performance. The trials demonstrated that the LSAT required approximately 40% less weight to sustain equivalent fire missions as the M249, due to the CT 's 40% weight reduction per round while maintaining comparable and range. Shot groups at 300 meters were tighter than those of the M249, attributed to the weapon's lighter barrel and improved balance, with no degradation in lethality observed across over 12,000 rounds fired. Recoil was reduced, enabling faster follow-up shots and better controllability in sustained bursts. The total system, including the weapon and 1,000 rounds of , achieved 20.4 pounds in weight savings over the M249 equivalent, directly enhancing gunner mobility during extended carries. Subsequent assessments in September 2011 at Fort Benning, Georgia, involved a two-week military utility evaluation with 19 soldiers from the , incorporating simulated squad maneuvers and scenarios to test integration into platoon-level operations. Procedures included a 6-mile march in full combat gear to quantify mobility gains, followed by urban live-fire exercises simulating room-clearing and bounding , where the LSAT provided while assistant gunners maneuvered. The lighter system—20.4 pounds total savings with ammunition—allowed gunners to cover more ground without fatigue, with measured improvements in squad repositioning speed during fire missions. Over 25,000 rounds were fired across eight prototypes, confirming the weapon's durability in dynamic settings. Environmental testing during these phases exposed prototypes to dust, mud, and temperature extremes ranging from -40°F to 140°F, as part of (TRL) 7 validation. The CT variant demonstrated superior reliability, with fewer stoppages in adverse conditions compared to the CL version, which faced challenges with caseless round integrity in humidity and rough handling; CT achieved over 14,000 rounds fired with minimal malfunctions prior to full TRL certification. In 2013 live-fire demonstrations at Fort Benning as part of the Army's Dismounted Non-Networked Experiment (DNNE), endurance testing pushed prototypes through approximately 10,000-round sequences, highlighting the LSAT's enhanced mechanical robustness. These results underscored the program's progress toward reducing logistical burdens while preserving effectiveness.

Comparative Performance Assessments

During the 2011 Military Utility Assessment at Fort Benning, Georgia, 79% of participating soldiers (15 out of 19) preferred the LSAT light machine gun over the incumbent M249 SAW, citing its significantly reduced weight as a key factor in lowering fatigue during extended operations, including a capstone 72-hour force-on-force exercise where lighter loadouts improved sustained mobility. Soldiers also reported enhanced accuracy in urban environments, attributed to the LSAT's shorter overall length and adjustable buttstock, which enabled 1 minute and 11 seconds faster completion times on obstacle courses simulating close-quarters maneuverability compared to the M249. In the 2013 Dismounted Non-Networked Experiment (DNNE) conducted by the U.S. Army Capabilities Integration Center at Fort Benning, the LSAT LMG demonstrated faster target engagement through quicker transitions between firing postures, a benefit of its lightweight design weighing approximately 10 pounds empty versus the M249's 17-20 pounds. Feedback from the assessment highlighted improved controllability during burst fire, with soldiers noting better sight picture maintenance and reduced recoil compared to the M249, partly due to enhanced bipod stability that minimized muzzle rise. These qualitative advantages contributed to higher overall maneuverability scores in comparative evaluations, where the LSAT's 41% weight reduction over the M249 led to better performance in dynamic scenarios. Expert evaluations from , the program's lead developer, emphasized logistical benefits, including up to 20.4 pounds of savings per 1,000-round basic load through lighter cased , equating to substantial reductions in transport volume and enabling 21,600 additional rounds per pallet in supply chains. However, reviews also identified drawbacks such as potential higher production costs for the specialized , estimated at several times that of traditional brass-cased rounds due to novel manufacturing processes. Drawbacks included frequent malfunctions requiring disassembly during testing, though these were less frequent than in initial prototypes. Input from approximately 20 testers across these evaluations informed design refinements, including adjustments to rail mounting systems for better accessory integration and , ensuring compatibility with standard equipment without compromising the weapon's lightweight profile.

Evolution and Legacy

Caliber and Variant Advancements

Following the initial success of the core 5.56mm LSAT design, post-2013 efforts focused on scaling the cased telescoped (CT) technology to larger calibers to enhance range, lethality, and versatility while preserving weight reductions. In 2014, the U.S. Army awarded Textron Systems a $5.7 million contract to develop a 7.62mm CT variant, including , a , and operating mechanism, building on the lightweight polymer-cased architecture. By 2016, delivered a 7.62mm CT prototype weighing 14.7 pounds, featuring a cyclic of 550 rounds per minute, open-bolt operation, and forward-feed gas system for improved . This variant maintained significant weight savings over conventional 7.62mm systems, achieving approximately 40% reduction in load compared to brass-cased equivalents, though scaling the CT design introduced challenges in optimization and structural integrity. Concurrent 2016 advancements explored a 6.5mm CT round, with akin to the 6.5mm , tested in and configurations for enhanced long-range performance. The 6.5mm variant demonstrated an effective range of up to 1,000 meters in applications. This caliber offered up to 45% weight savings versus traditional 7.62mm loads, improving soldier mobility without sacrificing penetration or accuracy. These efforts addressed scaling hurdles for larger CT ammunition while sustaining overall weight efficiencies.

Transition to Next Generation Programs

In 2017, the U.S. Army initiated the Next Generation Squad Weapon (NGSW) program to develop advanced small arms systems, effectively incorporating technologies from the Lightweight Small Arms Technologies (LSAT) program, including cased telescoped (CT) ammunition concepts, to address evolving combat requirements. By 2018, Textron Systems, the primary LSAT contractor, received a contract to prototype an automatic rifle for the NGSW's squad automatic rifle component, submitting designs derived from its LSAT light machine gun that utilized CT 6.8mm cartridges for enhanced lethality and reduced weight. These prototypes represented a direct evolution of LSAT innovations, aiming to replace the M249 SAW with a lighter, more capable system designated as the XM250. The NGSW competition progressed through prototype evaluations, but Textron's LSAT-derived entry faced challenges in meeting performance thresholds, particularly in reliability and integration with the program's fire control systems, leading to its elimination prior to the final downselect. In April 2022, the Army selected SIG Sauer's hybrid 6.8mm design for the XM250 automatic rifle, opting for conventional brass-cased ammunition over Textron's polymer CT approach due to concerns over long-term reliability, supply chain maturity, and compatibility with existing logistics. This decision marked a pivotal shift away from full LSAT CT adoption in the standard issue, though elements of the technology informed broader ammunition research. The LSAT program wound down following the NGSW selection, with its assets archived for historical and research purposes at . Despite not entering widespread service, LSAT's emphasis on weight reduction—achieving up to 41% lighter systems compared to legacy designs—influenced modern light machine guns like the XM250, which offers approximately 30% weight savings over the M249 while maintaining capability. As of May 2025, the XM250 achieved type classification standard status, with fielding underway to U.S. Army close combat units.

References

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