Mood picture: TEA module on pistol in training

THALES - Safety through optimal training

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Or how to put it another way: Practice makes perfect. Under the product name "TEA", a new analysis module for simulation weapons, airsoft weapons and real firearms was developed with Thales to support security forces in training. In close cooperation with the international electronics development department of Thales, an appealing product design and housing concept was developed that met all specifications.

The "TEA" (Tactical Engagement Analysis) product complements Thales' extensive portfolio of training and simulation products in the field of "Small Arms Training" and once again underlines the company's expertise in this product area.

The module enables a much more effective evaluation and reflection of the training session by recording the firing event, movement and attitude data, as well as video footage. Through the use of real-time AI-based evaluation, the central control unit enables trainees to optimize their technical skills, tactical know-how and decision-making under stress.

A look at the application itself clearly shows that any additional weight or disruptive element will affect the safety forces during the exercise session. For example, with an additional element on the handgun, the use of the holster can quickly become problematic or get stuck in the field during simulations.

If we now ignore the final use and only consider the challenges in development on the way to the finished product, the miniaturization of the housing clearly stands out as a result. The central focus was therefore on the most compact design, taking into account the inviolable electronic components. For this purpose, a close exchange between electronics and housing development took place in agile project steps and iteratively the concept was optimized step by step for this purpose.

Other initial concerns, such as heat generation at the barrel of the gun, turned out to be unproblematic in the course of the project. The critical heat generation at the processor was solved by selectively dissipating the heat via the housing.

Elastic mounting of the electronic components was integrated at an early stage to protect the components and compensate for tolerances. Practical tests showed that the battery also had to be protected against recoil during firing.

In order to enable flexible use with different weapons without the need for further expensive investments in housing tools, we decided in the course of the project to use an interchangeable adapter concept for different weapon systems such as the Picatinny rail.

Due to low volumes and tight deadlines, the decision was ultimately made to use rapid prototyping technology for all housing parts. On the one hand, this allowed many new options in terms of design, but on the other hand it presents new challenges in terms of tolerances and loadable material characteristics such as UV resistance, durability, E-modulus, impermeability, ... By means of corresponding samples and tests, this was coordinated and further developed step by step.

BUSSE Design+Engineering is pleased to have launched another sophisticated product with our customer Thales.

Detailansicht: Tactical Engagement Analysis Modul
Detailed view: Tactical Engagement Analysis Module on pistol

Our skills

Product design

CAD surface design

Housing construction

Design for manufacturability (DFM)

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Your contact person
Bernd Heckenberger, Head of Engineering, Project Manager
Bernd Heckenberger, Head of Engineering, Project Manager
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