Ballistic protection systems, carrying systems and tactical apparel for military, police and security forces
Mehler Vario System GmbH
Fulda (two plants) · Komenda (Slovenia)New on Amplifa
About Mehler Systems
Mehler Vario System GmbH (Mehler Systems), based in Fulda, is a manufacturer of ballistic body protection systems, platform and vehicle protection, modular carrying systems and tactical apparel. The group comprises the brands Mehler Protection (ballistic protection solutions), Lindnerhof (modular carrying systems) and UF PRO (tactical apparel). Manufacturing covers body armor systems with soft and hard ballistics (e.g. MOBAST for the German Armed Forces), anatomically shaped soft ballistic protection, ballistic helmets made of ultra-high-molecular-weight polyethylene and titanium, as well as the manufacture of uniform systems from nylon, flame-retardant materials (pyroshell™, PYRAD®) and GORE-TEX laminates. Development, production, testing procedures and quality assurance are carried out in-house, complemented by prototyping and a Body Armour Fitting Service. Customers include the German Armed Forces (Bundeswehr), the Swedish Armed Forces, and police and security authorities of several countries. The headquarters with two production plants is located in Fulda; tactical apparel (UF PRO) is developed and produced by UNI&FORMA d.o.o. in Komenda (Slovenia).
- Site
- Fulda
- Processes
- Manufacture of ballistic body armor (body protection systems), Manufacture of soft ballistics (anatomically shaped ballistic protection elements), Manufacture of ballistic helmets (Omega Core / Omega Hybrid), Manufacture of tactical apparel (uniforms, jackets, trousers), Manufacture of carrying systems / modular pouches (Lindnerhof), Platform and vehicle protection / protection systems for land, air and naval vehicles, Development and engineering of ballistic protection systems (prototyping and testing), Thermo-Man test procedure (3-second flashover test of FR apparel, performed by EMPA)
- Materials
- Ultra-high-molecular-weight polyethylene, Polyethylene (outer shell Omega Hybrid), Titanium (inner shell Omega Hybrid), Nylon, Nylon ripstop, Graphite (in pyroshell™ adhesive coating), pyroshell™ (Schoeller Textil AG), PYRAD® (W.L. Gore & Associates)
- Certificates
- In-house testing procedures and quality assurance, Thermo-Man test (EMPA)
- Founded
- 1837
- Employees
- approx. 650
- Industries
- Military and defense, Police and law enforcement, Security forces, Government agencies (German Armed Forces, NATO member states), Government agencies (e.g. German Armed Forces, NATO member states)
- 01
Development and engineering (prototyping)
- 02
Weaving/textile production
- 03
Manufacture of ballistic protection elements
- 04
Assembly/manufacture of body armor, helmets, carrying systems and apparel
- 05
Testing procedures and quality assurance
- 06
Body Armour Fitting Service and delivery
Materials and Processes
Ultra-high-molecular-weight polyethylene
Material of the ballistic helmets (Omega Core) and outer shells (Omega Hybrid), offering high protection at low weight
Titanium
Inner shell of the Omega Hybrid helmet for stable protective performance
Nylon / nylon ripstop
Base material of tactical apparel, also in combination with flame-retardant technologies
pyroshell™ (Schoeller Textil AG)
Adhesive coating with graphite that forms a non-combustible layer when exposed to heat (flame-retardant combat apparel)
PYRAD® (W.L. Gore & Associates)
Flame-retardant technology in FR jackets and rain jackets, reduces heat transfer and flame spread
GORE-TEX 3-layer laminate
Waterproof, breathable laminate in flame-retardant rain jackets
schoeller® dynamic stretch fabric
Elastic fabric for wearing comfort and freedom of movement in tactical apparel
Ballistic fibers
Material basis for soft and hard ballistics as well as anatomically shaped soft ballistic protection (FlexGuard)
Locations
Fulda
DEHeadquarters and production with two plants (second plant 26,000 m², opened in 2022)
- Materials
- Ballistic fibers, textiles, ultra-high-molecular-weight polyethylene, titanium
Komenda
SIProduction and development of tactical apparel (UF PRO / UNI&FORMA d.o.o.)
- Materials
- Nylon, nylon ripstop, pyroshell™, PYRAD®, GORE-TEX
Components and Products
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Manufacture of ballistic body armor (body protection systems)Assembly | – | – | – | – | ballistic fibers (unspecified), textiles |
| Manufacture of soft ballistics (anatomically shaped ballistic protection elements)Forming | – | – | – | – | innovative ballistic materials (unspecified) |
| Manufacture of ballistic helmets (Omega Core / Omega Hybrid)Assembly | – | – | – | – | ultra-high-molecular-weight polyethylene, polyethylene, titanium |
| Manufacture of tactical apparel (uniforms, jackets, trousers)Assembly | – | – | – | – | nylon, nylon ripstop, stretch fabric (schoeller® dynamic), GORE-TEX 3-layer laminate, PYRAD® (Gore), pyroshell™ (Schoeller) |
| Manufacture of carrying systems / modular pouches (Lindnerhof)Assembly | – | – | – | – | textiles |
| Platform and vehicle protection / protection systems for land, air and naval vehiclesEngineering | – | – | – | – | – |
| Development and engineering of ballistic protection systems (prototyping and testing)Engineering | – | – | – | – | – |
| Thermo-Man test procedure (3-second flashover test of FR apparel, performed by EMPA)Testing | – | – | – | – | – |
| Weaving / textile production (canvas weaving, historically since 1903)Other | – | – | – | – | textiles |
Additional services
Reference customers
Quality
Development, production, testing procedures and quality assurance are carried out in-house with a high level of value creation in Germany. Flame-retardant apparel is additionally tested under the Thermo-Man test procedure (3-second flashover test) by EMPA in Switzerland.
| Evidence | Fulda |
|---|---|
| In-house testing procedures and quality assurance | |
| Thermo-Man test (EMPA) |
History
- 1837
Founded by Valentin Mehler as a craft business for table linen in Fulda
- 1903
Specialization in sailcloth/canvas weaving under partner Arthur Kayser
- 1926
Start of clothing production
- 1980
Entry into the production of textiles for ballistic vests
- 1986
Foundation of Mehler Vario System GmbH as a specialist for body armor
- 1997
Foundation of UNI&FORMA d.o.o. (UF PRO) in Slovenia
- 2019
UNI&FORMA d.o.o. (UF PRO) becomes part of Mehler Systems
- 2022
Opening of the second 26,000 m² production plant in Fulda; Thomas Homberg becomes CEO; order for 305,000 MOBAST body armor systems from the German Armed Forces; order expansion for the Swedish Armed Forces
- 2024
Delivery of the 100,000th MOBAST system to Bw Bekleidungsmanagement GmbH; launch of the ExoM exoskeleton and the Omega helmet series; FR uniforms for the Dutch riot police
- 2026
TOP 100 award as an innovative mid-sized company