How HighCom’s XTclave™ Recommissioning Could Transform US Ballistic Protection
HighCom Limited has recommissioned its XTclave™ system in Ohio, doubling production capacity and setting the stage for new ballistic product launches in FY26. The move strengthens its collaboration with the U.S. Department of Defense and positions the company for significant government contract opportunities.
- XTclave™ system recommissioned at Columbus, Ohio facility
- Production capacity doubled with new ASME-certified pressure vessel
- U.S. personnel undergoing training for system operations
- Existing product lines to resume in Q1 FY26; new product line targeted for Q2 FY26
- Ongoing collaboration with U.S. Department of Defense under CRADA
Strategic Upgrade and Relocation
HighCom Limited (ASX, HCL) has successfully recommissioned its proprietary XTclave™ system at its manufacturing site in Columbus, Ohio, marking the culmination of an 18-month strategic initiative. Originally relocated from Australia in early 2024, the system has undergone significant enhancements, including the installation of a new water-based cooling system tailored to Ohio's climate and the construction of a larger, ASME-certified pressure vessel that doubles the system's capacity.
Enhanced Production Capabilities
The upgraded XTclave™ system can now complete at least three production cycles per shift, with an estimated annual output of up to 40,000 ballistic plates. This expanded capacity not only boosts volume but also broadens the range of products that can be manufactured, including helmets, shields, and complex armor geometries for aviation and vehicle applications. The technology’s ability to consolidate advanced composites into ultra-lightweight, high-strength ballistic products offers a competitive edge, particularly in the U.S. market.
Collaboration with U.S. Defence
HighCom’s recommissioning aligns with its ongoing collaboration with the U.S. Department of Defense, including a Cooperative Research and Development Agreement (CRADA) with the U.S. Army Development Command. This partnership facilitates joint development of next-generation ballistic solutions and secures research funding, positioning HighCom to compete for lucrative government contracts. Importantly, all XTclave™-produced products comply with the U.S. Berry Amendment, a key requirement for domestic defence procurement.
Product Pipeline and Market Outlook
HighCom plans to restart production of existing XTclave™ product lines in the first quarter of fiscal 2026, while targeting the commercial release of a new 'Superior' range of ultra-lightweight ballistic plates and helmets by the end of the second quarter. These products will undergo rigorous independent testing and seek National Institute of Justice certification to ensure market readiness and performance validation. Alongside XTclave™ offerings, HighCom will continue manufacturing its established 'Classic' and 'Enhanced' product ranges, maintaining a diversified portfolio to meet varied customer needs.
Looking Ahead
CEO Todd Ashurst highlighted the recommissioning as a pivotal milestone that enhances HighCom’s innovation capabilities and operational excellence. The company’s strengthened U.S. presence and advanced manufacturing technology set the stage for accelerated growth and leadership in the personal protection equipment sector, particularly within defence and law enforcement markets.
Bottom Line?
With XTclave™ fully operational and capacity doubled, HighCom is poised to capitalize on growing U.S. defence demand and upcoming product launches.
Questions in the middle?
- Will HighCom secure major U.S. Department of Defense contracts leveraging Berry Amendment compliance?
- How will the new 'Superior' product range perform in independent ballistic testing and certification?
- What is the timeline and scale for ramping up full production capacity beyond initial targets?