Step 1 - Smelting

The first step in our bullet manufacturing process is lead smelting. Our smelting vessel can contain up to 5 metric tons of metal. By producing our own lead (round ingots), we can control their hardness and quality. When the hardness of the lead alloy core is well-balanced, it allows for an optimal fit to a barrel’s internal profile. We systematically identify our production lots for traceability and quality assurance. Our foundry provides us with great flexibility in terms of manufacturing times, alloy specifications and cost control.

Step 2 - Extrusion and swaging

After leaving the smelting vessel, the lead (round ingots) are taken to a die to be extruded into perfectly round wires. Thanks to our extrusion process, no air bubbles are trapped inside the metal. As a result, we obtain a more uniform and dense metal.

The wire is then taken to a cold press for swaging. This process enables us to create bullets that are perfectly aligned to the dimensions and weight of the desired calibre. This step improves consistency from bullet to bullet for enhanced reliability.

Step 3 - Copper electroplating

Once placed in perforated containers, the lead cores are immersed in different chemical and electroplated copper solutions. This production step is important and requires great attention in order to ensure that the copper bonds perfectly with the lead. The strength of that bond has a direct influence on the quality of the bullets and sets our technique apart from copper jacketing.

Another characteristic that plays a considerable part in the quality of a bullet is the thickness of the copper layer. Our bullets are plated with a 200-micron (8 thousandth of an inch) copper layer. The thickness of the layer is directly proportional to the time required for the plating. To attain our manufacturing standards and specifications, the plating process requires more time than other suppliers that produce low-quality bullets.

Step 4 - Final swaging and polishing

Once the bullets are copper-plated, they are sent to hydraulic presses for final swaging. This step optimizes the precision of our bullets by giving them their final dimensions within extremely strict tolerances. During this process, special attention is given to the bullets' concentricity, eliminating any out-of-roundness surfaces. We also control the cylindrical character and parallelism of the bullet shape. Finally, we check the shape of the base. An irregular bullet base will make the propellant gases exit inconsistently, hence reducing the accuracy of the shot. All these details contribute to the gyroscopic stability of the bullet by ensuring that its trajectory reaches an optimal aerodynamic stability for an uber-precise shot.

Cleaning and polishing are the last steps of the manufacturing process, giving the CamPro copper bullets their signature shine—and the final quality touch that only our projectiles provide.