Optimizing civilian armored vehicle design with quality: A case study on lightweight ballistic protection using the DfA2 methodology

The global demand for ballistic protection systems within civilian armored vehicles (CAVs), particularly in high-security environments, necessitates focused research. Given the paucity of literature addressing the ballistic enhancements design of non-military passenger vehicles, this work concerns the analysis of quality assurance during the armoring process of a standard civilian passenger vehicle while maintaining its original functionality and consumer guarantees. To achieve these metrics, the article presents the Design for Assembly and Armoring (DfA2) methodology in a case study, examining the protection of a front door system of a worldwide compact sport utility vehicle (SUV). This systematic framework optimizes lightweight ballistic systems for CAVs through empirical evaluations and engineering principles. Integrating manufacturing acumen with Design for Excellence (DfX) principles, quality assurance protocols, automotive performance criteria, and ballistic defense requirements, DfA2 addresses the development and integration of armoring solutions with product and process quality in CAVs. Through field research, this study demonstrates the efficacy of the proposed method in refining armoring operations, minimizing armor material mass, and reducing production and design expenditures. Consequently, the findings of this case study with the adoption of DfA2 suggest that the method can be replicated or adapted for diverse vehicle categories, encompassing hatchbacks, notchbacks, SUVs, and commercial vehicles. This research sought to standardize vehicle armoring production, ensuring rigorous quality control while preserving original vehicle functionalities and consumer warranties.