INCA – FBT Fine Ballistic Tools

INCA Gun Suppressor | Technical Manual and Operating Instructions

FBT INCA Silencer Systems (HOT, AIR, ONE, TAC)
English

1. Introduction to Additively Manufactured Signature Reducer Technology

The development of silencers for small arms has undergone significant technological transformation in recent decades. While manufacturing was long dominated by machining processes such as turning and milling, the use of additive manufacturing—specifically Selective Laser Melting (SLM) of titanium powders—marks a paradigm shift in the design of ballistic suppression systems.

FBT Fine Ballistic Tools GmbH has positioned itself at the forefront of this technological evolution with the INCA product line. This document serves as comprehensive technical documentation and operating instructions for the silencers of the INCA family, comprising the HOT, AIR, ONE, and TAC series.

It is aimed at professional users, gunsmiths, and technically savvy sport shooters as well as hunters who require a profound understanding of the functionality, handling, and maintenance of these highly complex monolithic systems. Unlike conventional silencers, which often consist of an outer tube and a removable inner core (baffle stack), the INCA systems are characterized by a monolithic, i.e., “printed in one piece,” construction. This design philosophy requires a rethinking of handling, particularly regarding maintenance, as disassemble-ability was abandoned in favor of maximum structural integrity and weight-optimized internal geometries.

1.1 Objective and Scope of Application

The primary goal of this report is to provide standards-compliant and safety-oriented instructions for the operation of 3D-printed titanium silencers. While traditional manuals often describe step-by-step disassembly processes, this document focuses on the preventive maintenance of interfaces (threads) and the ballistic implications of the system. The instructions cover use in hunting scenarios, where the “Cold Bore Shot” and weight reduction are paramount, as well as sporting and tactical use, characterized by high rates of fire and thermal stress. The procedures and warnings described here apply specifically to the material combinations of Titanium Grade 5/23 and carbon composites, as used in the INCA series.

1.2 Evolution of the INCA Series: From Concept to Production

The name INCA stands programmatically for the integration of modern materials. Development began with the objective of eliminating the disadvantages of classic steel silencers (high weight, susceptibility to corrosion) and aluminum silencers (low heat resistance, erosion). By using titanium in 3D printing, internal structures could be realized that are fluid-dynamically optimized without being limited by the restrictions of CNC milling tools. This enabled the creation of a closed material structure and a design that efficiently swirls and cools the gas volume before it leaves the muzzle.

The product family is divided into four specialized application areas: the robust HOT series for maximum load, the light AIR series with mirage protection, the integrated ONE series for aesthetic symbiosis with the weapon, and the tactical TAC series for semi-automatic and automatic systems.

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2. Normative References and Safety Regulations (EU Conformity)

The operation of silencers is subject to strict regulations in the European Union as well as in the national legislation of member states. This manual aligns with the requirements of EU Directive 2003/10/EC on the protection of workers from risks related to noise exposure as well as relevant proof laws.

2.1 Legal Classification and Acquisition Requirements

In most European jurisdictions, silencers are treated legally equivalent to the firearms for which they are intended. This means the silencer is considered an essential firearm component. Acquisition and possession usually require a permit. In Austria and many German federal states, acquisition is released for holders of valid hunting licenses under certain conditions.

• Transport: When traveling within the EU, the European Firearms Pass is required.
• Mounting: Retroactively adding a muzzle thread to a barrel constitutes an essential modification (often requiring re-proofing).
• Caliber Restrictions: The use of a silencer is strictly limited to the caliber group approved for it.

2.2 Health Protection and Noise Emission

The EU Noise Directive defines exposure limit values (max 137 dB(C)). INCA silencers reduce the muzzle report by 29 dB to 37 dB depending on the model and caliber. However, the supersonic crack of the projectile (Sonic Boom) cannot physically be eliminated. Wearing additional hearing protection is recommended.

2.3 Fundamental Safety Rules for Handling

• Load Status: Before any manipulation, the weapon must be unloaded.
• Temperature: Acute risk of burns after firing! Titanium can reach several hundred degrees.
• Foreign Objects: Check for foreign objects or fluid in the silencer before firing (risk of hydraulic rupture).

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3. Detailed Product Description of the INCA Series

3.1 INCA HOT Series: The High-Performance Reference

100% 3D-printed titanium series for maximum load.

• Usage Profile: Driven hunts, shooting cinemas, Magnum hunting, Long Range.
• Features: Special surface structure for heat dissipation and secure grip.
• Durability: No caliber can overload the HOT series (including .338 Lapua Mag).

3.2 INCA AIR Series: Ultralight and Mirage-Free

The answer to the requirements of mountain hunting.

• Technology: Hybrid construction (Titanium Core, Carbon Tube, Ceramic Insulation).
• Anti-Mirage Effect: The carbon shell isolates heat, preventing warm air from rising in front of the scope.

3.3 INCA ONE Series: The Integral Solution

Integral silencers enclosing the barrel.

• Concept: Utilizes volume around the barrel for gas expansion without excessive length increase.
• Design: Slim diameter (31mm) often allowing use of open sights.

3.4 INCA TAC Series: Tactical Efficiency

For semi-automatic and automatic platforms.

• Low Backpressure: Internal geometries minimizing gas return (“Overgassing”).
• QD Mounting: Quick attachment on standardized flash hiders (e.g., NATO A2).
• Material: Titanium Grade 23 or INCONEL 718 for extreme heat resistance (continuous fire).

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4. Mounting and Adapter Systems

4.1 The M22x1 Base Thread

The silencer features a uniform M22x1 fine thread at the rear. It is not tied to a single barrel thread; only the adapter needs to be swapped when changing weapons.

4.2 Thread Adapter Installation

• Cleaning: Clean M22x1 and adapter threads.
• Insertion: Screw in by hand without tilting (risk of titanium galling).
• Fixation: Gluing the adapter into the silencer with Loctite 243 (blue) is recommended.
• Tightening: Torque approx. 25-30 Nm.

4.3 Mounting on the Weapon

• On-Barrel: Screwed onto the front of the muzzle.
• Over-Barrel: Extends back over the barrel. The rear plastic guide ring must have at least 0.5mm clearance (serves as protection, not support).

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6. Maintenance and Care: The Monolithic Concept

INCA silencers are non-disassemble-able.

6.1 “Maintenance-Free” – Myth and Reality

Titanium does not corrode, but cleaning is necessary to maintain functionality and protect the thread.

6.2 Permissible Cleaning Procedures

• Through Bore: Every 200-500 shots with a nylon/bronze brush.
• Thread Care: Clean regularly. Use exclusively ceramic paste (Anti-Seize). Never use oil or grease (risk of coking).
• Exterior Cleaning: Water/soap for Titanium (HOT), damp cloth for Carbon (AIR/ONE).

6.3 Prohibited Measures

• No ultrasonic baths for HOT/AIR/ONE (risk of structural damage). Allowed for TAC.
• No chemical baths (risk of fluid retention in pores and subsequent corrosion).
• Never attempt to open the silencer.

6.4 Storage (Important!)

Unscrew the silencer after every use! Humidity and residue form acids that destroy the barrel if the silencer remains mounted. Store upright to allow chimney effect.

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8. Error Diagnosis (Troubleshooting)

Symptom	Possible Cause	Remedy
Loss of precision (group opens up)	Silencer loose	Check tightness (retighten hand-tight).
	Adapter loose	Check adapter. Re-glue if necessary.
	Baffle Strike	Check exit opening. If contact traces: STOP. Check barrel thread.
Silencer cannot be unscrewed	Thread seized	Let cool completely. Penetrating oil (carefully).
	Coking	If oil burned in thread: Light taps with rubber mallet. Future: Ceramic paste.
Heat mirage	Extreme firing sequence	Let cool. Use FBT mirage band.

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