Composite Materials: The Edge of Battlefield Camouflage

Tomorrow is Veterans Day in the United States, a holiday that began as Armistice Day to honor the World War I fallen. That era also introduced modern camouflage, with the French Army establishing the first dedicated unit in 1915, as noted by the British Imperial War Museums website. Over the decades, the materials and techniques used to conceal soldiers have evolved dramatically. Patrick Loock, Segment Business Owner for Products and Applications at Exel Composites, shares insights on how composite tubes support camouflage nets in an interview with PlasticsToday.

“Concealing presence, position, and intent is vital for battlefield effectiveness. Camouflage netting support units must endure heavy loads, be quickly dismantled, and perform in extreme environments,” says Loock.

For telescoping poles that hold camouflage nets, composites are preferred over aluminum because they offer lighter weight, greater robustness, and faster assembly. The tubes must be strong enough to support heavy nets while remaining flexible enough to handle variable loads.

Fiberglass: A Long‑Standing Battlefield Ally

Since World War II, fiberglass—an engineered polymer reinforced with glass fibers—has been the material of choice for defense. Engineers first used it for aircraft radomes, replacing molded plywood. Today, armed forces worldwide employ fiberglass for its corrosion resistance, weather tolerance, competitive cost, and design flexibility.

Fiberglass’s high tensile strength makes it ideal for netting supports. It also acts as a superior insulator, with a lower thermal conductivity than aluminum, rendering it largely invisible to thermal imaging cameras commonly used on the battlefield.

Fiber Alignment: The Secret to Strength

Material choice is only part of the equation; fiber alignment achieved through the manufacturing process is equally crucial. Loock notes that pull‑winding—where fibers, mats, and fabrics are guided and resin‑saturated—provides a helical alignment that combines cross‑wise and unidirectional fibers. The result is a thinner wall with the necessary strength and stiffness for support.

Color durability is also essential. When aluminum or other materials are rapidly dismantled or handled roughly, surface paint can chip, compromising concealment. To safeguard color integrity, NATO green or sand pigments are incorporated directly into the resin. This technique ensures that even deep scratches leave the same hue visible across the tube wall.

Thermoset Resins: Reliable Performance

Choosing the right resin is critical. Thermoset resins are employed for camouflage netting support units because they lock into shape over their lifespan and offer superior chemical resistance compared to epoxies.

Composites also provide flexibility under varied loads and extreme temperatures, maintain stretching tolerances, and resist impact. Even if a bullet punctures the support unit, the structure remains functional. Moreover, composites are rust‑free, water‑resistant, and well suited for wet terrains.

Headquartered in Finland, Exel Composites boasts more than 60 years of experience in fiber‑reinforced plastics across a wide array of applications. With a global footprint that includes a facility in Erlanger, KY, the company partners with military forces to deliver lightweight, portable, and rugged composite systems capable of withstanding rough handling and harsh environmental conditions.