Rifleman Q&A: Making Non-Toxic Pellets

by
posted on November 11, 2022
Pellet Manufacturing Kent Cartridge
Image courtesy of Kent Cartridge

Q. I’ve heard that traditional shot pellets are made by dropping molten lead through a sieve in something called a shot tower. Today we seem to have such a variety of shot to choose from, all of which look very different from one another. What are the methods of manufacture for some of today’s non-toxic shot?


A. Non-toxic pellets are made using various processes. Some involve smelting metals while others rely on compression forming and molding. Steel shot is formed by cutting precise lengths of soft-iron or steel wire of the desired pellet diameter. The snippets are then annealed to soften them and rolled under pressure to make them round. Now work-hardened, they are again annealed to make them as soft as possible. Following the last annealing, the pellets are polished by tumbling.

Kent’s Tungsten-Matrix pellets are made by mixing powdered tungsten with a thick goo-like polymer that evenly suspends the micro-fine powder until the polymer cures. The mixture is then formed into thin ribbons from which the pellets are formed. Once hardened, the excess is removed from the round pellets and recycled.

Bismuth shot is made by melting bismuth with about 3 percent tin for increased malleability. Bismuth shot is made using the Bleimeister process that drops the molten bismuth/tin through a sieve perforated with holes the diameter of the shot to be formed. The molten pellets drop approximately three feet into hot water that cools them sufficiently to solidify the pellets. Once formed and dried, the pellets are polished prior to loading. Large bismuth pellets are cast in molds.

The carbonless iron/tungsten pellets made by Federal—as well as Remington’s and Olin/Winchester’s tungsten-bronze pellets—are formed by mixing the powdered components, then forming the pellets in a mold under high pressure. Once formed, the pellets are sintered, which heats them to just below their melting point to further amalgamate the metals.

EnviroMetal’s Hevi-Shot is formed by smelting. Tungsten has one of the highest melting points of all metals, 3,410 degrees Celsius—nearly 7,000 degrees Fahrenheit. EnvironMetal’s Hevi-Shot requires melting tungsten with iron and nickel that is then dropped through a sieve onto a table where the pellets cool.

—John M. Taylor


This “Questions & Answers” was featured in the January 2007 issue of American Rifleman. At time of publication, "Questions & Answers" was compiled by Staff, Ballistics Editor William C. Davis, Jr., and Contributing Editors: David Andrews, Hugh C. Birnbaum, Bruce N. Canfield, David R. Chicoine, O. Reid Coffield, Charles Q. Cutshaw, Charles M. Fagg, Angus Laidlaw, Evan P. Marshall, Charles E. Petty, Robert B. Pomeranz, O.D., Jon R. Sundra, Jim Supica, A.W.F. Taylerson, John M. Taylor and John W. Treakle.

To subscribe to the magazine, visit the NRA membership page and select American Rifleman as your member magazine.

Latest

John Parker flowing piece flintlock muzzleloader right-side view on white background
John Parker flowing piece flintlock muzzleloader right-side view on white background

Captain John Parker's Fowler: Witness To History

While thousands of firearms were used in and around the Massachusetts towns of Lexington and Concord on April 19, 1775, few survive today. One survivor is the flintlock fowler used by Capt. John Parker of the Lexington militia.

New For 2025: Mossberg 590M Standoff & 500 Slugster Pump Shotguns

The Mossberg 500 is one of the most popular pump-action shotguns ever made. That doesn’t keep the company from making updates and improvements, as evidenced in the new-for-2025 590M Standoff and 500 Slugster series.

Preview: Warthog Sharpeners V-Sharp Elite A4

Warthog USA’s V-Sharp Elite A4 pairs the company’s most feature-packed portable blade-sharpening unit with a detachable wooden base for added stability.

The Men & Guns Of Lexington Green

On April 19, 1775, 250 years ago, approximately 80 armed militiamen from Lexington gathered on their village green to confront several hundred British infantrymen. The events of that morning began a conflict that would ultimately establish the United States of America.

"Battle Road" & The British Retreat To Boston: 250 Years Later

After the fights at Lexington and Concord's North Bridge, the British column had to return to Boston. On its way, the regulars were set upon by hundreds, then thousands, of armed militiamen hell bent on revenge.

Preview: Hawke Airmax 2-7X 32 mm AO

Shooters looking to add optics to their air rifles should choose airgun-specific scopes such as those in Hawke’s Airmax line—which offers four models.

Interests



Get the best of American Rifleman delivered to your inbox.