Polystyrene, resin, rotational moulding: the industrial process behind MilDecPro decoys.
Inherited from 30 years of civilian manufacturing by Green City, this process offers robustness, modularity and a cycle cost with no equivalent in the military decoy field.
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A process mastered for over 10 years in civilian use, applied to defence since 2025. CAD precision, series repeatability, short production lead time.
Hot-wire cutting
Decoys are cut from a block of high-density expanded polystyrene (20 to 30 kg/m³) by a numerically controlled hot wire. Millimetre precision, series repeatability, no significant solid waste.
Resin coating
Parts are coated with a two-part resin applied in successive layers. The resin hardens the surface, absorbs impact and resists dense vegetation. Long-term weather resistance with no maintenance.
UV paint
Two-part paint resistant to UV and abrasion. Camouflage tailored to the theatre by tint, pattern and surface finish. Confirmed durability of 10 to 20 years outdoors.
The kayak process, applied to the battlefield.
Rotational moulding produces hollow parts in mass-coloured polyethylene, the same way a canoe-kayak or a fuel tank is made. It is the basis of the Green Stone range: tactical rocks, rockfall walls and tactical furniture. A material that never failed in 30 years of intensive civilian use.
Credible decoys across every sensor.
Thermal signature
12 V heating elements simulating engine or crew heat. Temperature-rise profile configurable to the season and theatre.
Radar signature
Passive corner reflectors amplify the radar cross-section so a polystyrene decoy becomes detectable by area-surveillance and SAR sensors.
Acoustic signature
On the roadmap: reproduction of characteristic acoustic emissions to defeat sound-ranging and multi-sensor fusion.