The U.S. Army Combat Capabilities Development Command Armaments Center unveiled the SixPAC, a new ammunition packaging system that combines lightweight polymer containers with a steel outer pack for 6.8-millimeter cartridges.
The system represents the first major overhaul of small-caliber ammunition packaging since World War II, replacing wooden boxes that required manual assembly and were susceptible to mold. The redesign addresses supply chain vulnerabilities, rising costs, and the need to prepare for military operations in varied climates, the center said.
The polymer inner pack reduces weight and enables easier transport, while the steel outer pack increases pallet density and reduces environmental impact by eliminating chemical wood preservative treatments. The lighter inner container—expected to weigh about half as much as legacy steel containers—will reduce the load on soldiers and improve the capabilities of weight-sensitive platforms like light watercraft and aircraft.
The design also expands the manufacturing base: more than 800 U.S. injection molders can potentially produce the polymer packs, creating competition and lowering barriers to entry for suppliers. Soldiers tested the SixPAC throughout 2024 and 2025. Several service members noted that aboard watercraft or aircraft, "every ounce counts" and the new system will allow them to carry more ammunition.
"This decision comes out of necessity—polymers aren't yet as proven in the U.S. as they are in other countries," said Jason Runell, the project's technical lead. "However, the U.S. must be ready to engage at any time and fight in various climates, all with their own difficulties and needs."