Patent Publication Number: US-2023140091-A1

Title: Ammunition magazine pouch and methods of assembling same

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 17/980,464, filed Nov. 3, 2022, which claims the benefit of U.S. Provisional Patent Application Ser. No. 63/275,266, filed on Nov. 3, 2021, the disclosure of which are hereby incorporated by reference in its entirety for all purposes. 
    
    
     FIELD OF THE INVENTION 
     This invention relates generally to an ammunition magazine pouch and a molding assembly for forming the ammunition magazine pouch. 
     BACKGROUND OF THE INVENTION 
     Law enforcement personal typically wear duty belts with equipment that includes but is not limited to a holstered handgun, holstered taser, holstered pepper-spray, and spare ammunition. Law enforcement personal are required to carry spare ammunition magazines on their duty belt. The device for holding the spare ammunition magazines in this case are critical because they can limit the speed of access to the magazines when re-loading the handgun. However, the size of the case must be as small as possible so that the positioning on the duty belt is comfortable for the police officer. 
     The present invention addresses one or more of the aforementioned challenges. 
     SUMMARY OF THE INVENTION 
     In one aspect of the present invention, an ammunition magazine pouch is provided. The ammunition magazine pouch includes a magazine support assembly including an interior surface defining a magazine chamber extending between an open top end and a closed bottom end. The magazine chamber is sized and shaped to receive at least one ammunition magazine therein. The magazine support assembly includes a front cover member including an inner surface defining a portion of the magazine chamber, a back plate member coupled to the front cover member to define the magazine chamber therebetween, and a tensioning assembly coupled to the front cover member and the back plate member for adjusting a distance between an upper portion of the front cover member and an upper portion of the back plate member to adjust a width of the open top end of the magazine chamber. 
     In another aspect of the present invention, a method of manufacturing an ammunition magazine pouch is provided. The pouch includes an interior surface defining a magazine chamber configured to receive an ammunition magazine therein. The method includes thermoforming a front cover member from a first sheet of thermoplastic material and thermoforming a back plate member from a second sheet of thermoplastic material. The method also includes stitching the back plate member to an attachment assembly and coupling the front cover member to the back plate member to define the magazine chamber therebetween extending between an open top end and a closed bottom end. The method also includes coupling a tensioning assembly to the front cover member and the back plate member to adjust a distance between an upper portion of the front cover member and an upper portion of the back plate member to adjust a width of the open top end of the magazine chamber. 
     In a further aspect of the present invention, a system for manufacturing an ammunition magazine pouch is provided. The system includes a thermoplastic machine assembly including a support frame, a heat press machine mounted to the support frame, a vacuum forming machine assembly mounted to the support frame adjacent to the heat press machine, and a support sled slideably coupled to the support frame and movable between the heat press machine and the vacuum forming machine. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein: 
         FIGS.  1 A- 20    are perspective views of an ammunition magazine pouch, according to embodiments of the present invention; 
         FIGS.  21  and  22    are exploded perspective views of the ammunition magazine pouch including a magazine support assembly and an attachment system; 
         FIGS.  23 - 29    are perspective views of portions of the magazine support assembly including a front cover member and a back plate member; 
         FIGS.  34  and  35    are perspective views of the back plate member and the attachment system; 
         FIGS.  43 - 46    are perspective views of a thermoplastic machine assembly for use in manufacturing the ammunition magazine pouch, according to embodiments of the present invention; 
         FIGS.  47 - 48    are perspective views of a CNC milling machine for use in manufacturing the ammunition magazine pouch, according to embodiments of the present invention; 
         FIGS.  49 - 62    are perspective views of mold assemblies for use in manufacturing the ammunition magazine pouch, according to embodiments of the present invention; and 
         FIG.  63    is a flowchart illustrating a method of manufacturing the ammunition magazine pouch, according to embodiments of the present invention. 
     
    
    
     Corresponding reference characters indicate corresponding parts throughout the drawings. 
     DETAILED DESCRIPTION OF THE INVENTION 
     In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one having ordinary skill in the art that the specific detail need not be employed to practice the present invention. In other instances, well-known materials or methods have not been described in detail in order to avoid obscuring the present invention. 
     In general, the present invention describes a tactical pouch  10  for use in securing tactical gear and ammunition magazines to traditional, micro and laser cut Molle attachment systems as well as slide on tactical and/or utility belts. For example, the tactical pouch  10  may be used to hold tactical gear such as CAT Tourniquets, telescoping batons, and/or any suitable tactical gear. The tactical pouch  10  may also be used to hold ammunition magazines such as, for example, .40, 9 mm, and .357sig double stack magazines, AR15 magazines, and/or any suitable ammunition magazine. 
     Referring to  FIGS.  1 A- 42   , in the illustrated embodiment, the present invention includes an ammunition magazine pouch  10  that includes a magazine support assembly  12  and an attachment system  14 . The magazine support assembly  12  includes an interior surface that defines a magazine chamber  16  extending between an open top end  18  and a closed bottom end  20 . The magazine chamber  16  is sized and shaped to receive at least one ammunition magazine  22  therein. The magazine support assembly  12  includes a front cover member  24  including an inner surface defining a portion of the magazine chamber  16 , a back plate member  26  coupled to the front cover member  24  to define the magazine chamber  16  therebetween, and a tensioning assembly  28  coupled to the front cover member  24  and the back plate member  26 . The tensioning assembly  28  is configured to adjust a distance between an upper portion of the front cover member  24  and an upper portion of the back plate member  26  to adjust a width of the open top end of the magazine chamber  16 . In some embodiments, the ammunition magazine pouch  10  is sized to hold the plurality of ammunition magazines side by side, for example, the left side of one of the ammunition magazines faces the right side of the second magazine. 
     Referring to  FIGS.  23 - 29   , in the illustrated embodiment, the front cover member  24  includes a pair of opposing sidewalls  30  extending outwardly from a front endwall  32 , a bottom endwall  34  extending between the front endwall  32  and the opposing sidewalls  30 , a support flange  36  extending outwardly from the opposing sidewalls  30  and the bottom endwall  34 , and a pair of opposing raised fastening support members  38  extending outwardly from the opposing sidewalls  30  defined near the open top end of the magazine support assembly  12 . The front cover member  24  is coupled to the back plate member  26  such that the support flange  36  contacts a front surface of the back plate member  26 . In some embodiments, the support flange  36  of the front cover member  24  is coupled to the front surface of the back plate member  26  with an adhesive. In some embodiments, the front cover member  24  is formed of a unitary body including a thermoplastic material. 
     Each raised fastening support member  38  includes an inner surface spaced a distance from the back plate member  26  to define a gap  40  between the inner surface of the raised fastening support member  38  and the back plate member  26 . 
     In some embodiments, the front cover member  24  includes a pair of recessed channels  42  defined along an outer surface of the front cover member  24  and extending from the front endwall  32  to the bottom endwall  34 . Each recessed channel  42  defines a corresponding dividing ridge  44  extending into the magazine chamber  16  to define a plurality of magazine compartments  46  within the magazine chamber  16 . Each magazine compartment  46  is sized and shaped to receive a corresponding ammunition magazine  22  therein. In some embodiments, the front cover member  24  includes a plurality of drain openings  48  spaced along the bottom endwall  34 . 
     Referring to  FIGS.  30 - 34   , in the illustrated embodiment, the back plate member  26  includes a support plate  50  having a substantially rectangular cross-sectional shape extending between a front surface  52  and rear surface  54 . The front surface  52  defines a portion of the magazine chamber  16  and includes a pair of raised positioning members  56  extending into the magazine chamber  16 . Each raised positioning member  56  is orientated with respect to a corresponding dividing ridge  44  of the front cover member  24  and spaced a distance from the corresponding dividing ridge  44  to define the plurality of magazine compartments  46 . The support plate  50  may also include an arcuate surface  58  extending along a top portion of the support plate  50  to define the open top end of the magazine chamber  16 . In some embodiments, the back plate member  26  is formed of a unitary body including a thermoplastic material. 
     Referring to  FIGS.  1 A- 20   , in the illustrate embodiment, the tensioning assembly  28  includes a plurality of adjustable fastening members  60  coupled between the front cover member  24  and the back plate member  26 . The plurality of adjustable fastening members  60  includes a pair of opposing outer fastening members  62  coupled to the opposing raised fastening support members  38  and the back plate member  26 . For example, the outer fastening member  62  may include a press-fit threaded insert  64  mounted to the back plate member  26  and a fastening screw  66  extending from the raised fastening support member  38  and into the press-fit threaded insert  64 . 
     The tensioning assembly  28  may also include a pair of inner fastening members  68 . Each inner fastening member  68  may be positioned within a corresponding recessed channel  42  and extend outwardly from a corresponding dividing ridge  44  to the back plate member  26 . For example, the inner fastening member  68  may include a press-fit threaded insert  64  coupled to corresponding dividing ridge  44  and a fastening screw  66  extending from the corresponding dividing ridge  44  and into the press-fit threaded insert  64 . 
     Referring to  FIGS.  34 - 42   , in the illustrated embodiment, the attachment system  14  is coupled to a rear surface of the back plate member  26  and is configured to facilitate mounting the ammunition magazine pouch  10  to a Molle mounting system and/or tactical belt. The attachment system  14  includes an attachment member  70  including an attachment body  72  having a substantially rectangular cross-sectional shape and a mounting strap  74  extending outwardly from a top end of the attachment body  72 . In some embodiments, the attachment system  14  may include a pair of mounting straps  74  extending outwardly from a top end of the attachment body  72 . 
     The attachment system  14  may also include a snap button assembly  76  (shown in  FIG.  14   ) including a stud assembly  78  coupled near a bottom end of the attachment body  72  and a socket assembly  80  coupled to a distal end of the mounting strap  74 . The mounting strap  74  is adapted to fold along the top end of the attachment body  72  to fasten the corresponding socket assembly  80  to the stud assembly  78 . In some embodiments, the attachment member  70  is formed of a unitary body including a polymer-coated fabric composite material. The back plate member  26  may also include a stud opening  82  for coupling the stud assembly  78  to the back plate member  26  through the attachment body  72 . 
     The attachment system  14  also includes a pair of locking tabs  84  coupled to the attachment body  72  and oriented substantially perpendicular to the mounting strap  74 . Each locking tab  84  extends between opposing ends that are coupled to the attachment body  72  to allow the mounting strap  74  to be positioned between each locking tab  84  and the attachment body  72  to facilitate mounting the ammunition magazine pouch  10  to a Molle mounting system and/or tactical belt. 
     In some embodiments, the back plate member  26  may include a plurality of recessed stitching channels  86  (shown in  FIG.  34   ) defined along a front surface of the back plate member  26 . The recessed stitching channels  86  are sized and shaped to receive stitching for coupling the attachment body  72  to the support plate  50 . 
     In some embodiments, the attachment system  14  includes the Hyperlock™ Attachment System provided by Safe Life Defense™. The Hyperlock™ Attachment System is an ultra-low profile, lightweight &amp; durable assembly constructed of a Polymer-Coated Cordura® Fabric Composite that allows for easy mounting to nearly anything. Hyperlock™ securely attaches to traditional, mico and laser cut molle as well as slide on belts between 1.5″-2.25.″ The Hyperlock™ Attachment System includes dual locking tabs at the bottom of the pouch that are specific to the gear the system is mounting to. A top locking tab is used for Micro Molle and 1.5″-2″ slide on belts, and a bottom locking tab is used for Traditional Molle and 2.25″ slide on belts. 
     In some embodiments, the front cover member  24  of the magazine support assembly  12  includes a plurality of sidewalls extending outwardly from the support flange  36  to form the magazine chamber  16  that is sized and shaped to receive an ammunition magazine therein. The front endwall  32  is spaced from the support flange  36  along a first axis (e.g., a Z-axis) and extends between the bottom endwall  34  and the left and right sidewalls  30 . The bottom endwall  34  is spaced a distance from the open top end  18  along a second axis (e.g., a Y-axis) that is perpendicular to the first Z-axis. The left sidewall is spaced a distance from the right sidewall along a third axis (an X-axis) that is perpendicular to the first Z-axis and the second Y-axis. 
     In one embodiment, the open top end  18  is configured to receive the plurality of ammunition magazines. The bottom endwall  34  is configured to support and hold the at least one ammunition magazine within the ammunition magazine pouch  10 . The front cover member  24  includes a plurality of recessed channels  42  and a pair of raised fastening support members  38 . Each recessed channel  42  defines a corresponding magazine compartment  46  configured to receive and house at least one ammunition magazine. Each raised fastening support member  38  is configured to receive the tensioning assembly  28  to couple the front cover member  24  to the back plate member  26 . 
     In various embodiments, the front cover member  24  includes a plurality of fastener openings  88  configured to receive the tensioning assembly  28 . The tensioning assembly  28  includes a plurality of adjustable fastening members  60 . Each of the plurality of fastener openings  88  on the front cover member  24  includes a cylindrical inner surface extending through the front endwall  32  and is sized and shaped to receive the adjustable fastening members  60  therein. In one embodiment, the front cover member  24  is coupled to the back plate member  26  via the one or more adjustable fastening members  60 . The adjustable fastening members  60  includes a press-fit threaded insert  64  that is coupled to the back plate member  26  and a fastening screw  66  inserted through a corresponding fastener openings  88  defined through the front cover member  24  and threadably coupled to the press-fit threaded insert  64  to facilitate coupling the front cover member  24  to the back plate member  26 . In some embodiments, the fastening screw  66  includes a head diameter equal to 0.2090 inches. In other embodiments, the fastening screw  66  may include any suitable head diameter. 
     The back plate member  26  includes a support plate  50 . The flexible attachment member  70  is coupled to a rear surface of the support plate  50  and includes a plurality of locking tabs  84  coupled to a rear surface of the flexible attachment member  70 . The back support plate  50  includes a substantially rectangular-shaped that includes the front surface  52  and the rear surface  54  along the first Z-axis. The support plate  50  extends between a bottom end, a top end, a left side, and a right side. The bottom end is spaced a distance from the top end along the second Y-axis. The left side is spaced a distance from the right side along the third X-axis. The back plate member  26  further includes at least one raised positioning members  56  having a substantially rectangular shape and extending outwardly from the front surface  52 . The raised positioning members  56  extends into the magazine chamber  16  defined between the front cover member  24  and the back plate member  26  and is sized and shaped to assist in holding the ammunition magazine in place in the ammunition magazine pouch  10 . 
     The flexible attachment member  70  includes the attachment body  72  that includes a front surface  90 , a rear surface  92 , a top end, a bottom end, a left side, a right side, a pair of mounting straps  74  and a plurality of openings  94 . The front surface  90  is spaced a distance from the rear surface  92  along the first Z-axis. The top end is spaced a distance from the bottom end along the second Y-axis and the left side is spaced a distance from the right side along the third X-axis. The pair of mounting straps  74  extend out from the top end along the second Y-axis. The plurality of openings  94  are configured to receive the snap button assembly  76 . Each of the plurality of openings  94  on the flexible attachment member  70  includes a cylindrical inner surface extending through the front surface  90  and is sized and shaped to receive the snap button assembly  76  therein. The front surface  90  of the flexible attachment member  70  is coupled to the rear surface  54  of the back plate member  26 . 
     In one embodiment, the pair of mounting straps  74  are configured to attach the ammunition magazine pouch  10  to a utility belt. Each mounting strap  74  includes at least one hole where each hole includes a cylindrical inner surface extending between the front surface  90  and the rear surface  92  and is sized and shaped to receive the socket assembly  80  therein. The pair of mounting straps  74  can then be bent to snap and secure the ammunition magazine pouch  10  to the utility belt. 
     The pair of locking tabs  84  includes a top locking tab  96  and a bottom locking tab  98 . The top locking tab  96  includes a front side, a back side, a top end, a bottom end, a left side, and a right side. The front side is spaced a distance from the back side along the first Z-axis. The top end is spaced a distance from the bottom end along the second Y-axis and the left side is spaced a distance from the right side along the third X-axis. The bottom locking tab  98  includes a front side, a back side, a top end, a bottom end, a left side, and a right side. The front side is spaced a distance from the back side along the first Z-axis. The top end is spaced a distance from the bottom end along the second Y-axis and the left side is spaced a distance from the right side along the third X-axis. The back side of the top locking tab  96  and the back side of the bottom locking tab  98  are partially coupled to the rear surface  92  of the flexible attachment member  70 . The top locking tab  96  is spaced a distance from the bottom locking tab  98  along the second Y-axis. The top locking tab  96  and the bottom locking tab  98  are configured to assist in coupling the ammunition magazine pouch  10  to, for example, a utility belt. In one embodiment, shown in  FIG.  14   , the bottom locking tab  98  includes a slit extending between the left and right side along the second Y-axis. 
     Referring to  FIGS.  43 - 62   , in some embodiments, the present invention describes a system  100  for manufacturing the tactical pouch  10 . The system  100  includes a thermoplastic machine assembly  102  and a Computerized Numerical Control (CNC) milling machine  104 . The thermoplastic machine assembly  102  includes a support frame  106 , a heat press machine  108  mounted to the support frame  106 , a vacuum forming machine assembly  110  mounted to the support frame  106  and positioned adjacent to the heat press machine  108 , and a support sled  112  slideably coupled to the support frame  106 . The heat press machine  108  is configured to apply a heat and pressure treatment to a sheet of thermoplastic material to facilitate thermoforming the thermoplastic material. 
     The vacuum forming machine assembly  110  includes a mold support frame  114  for supporting a mold assembly  116 , a hydraulic lifting assembly  118  coupled to the mold support frame  114 , and a vacuum pressure system  100 . The hydraulic lifting assembly  118  is configured to move the mold support frame  114  between a first vertical position (shown in  FIG.  43   ) and a second vertical position (shown in  FIG.  44   ). The vacuum pressure system  100  is coupled to the mold support frame  114  and configured to apply a vacuum pressure to the mold assembly  116  with the mold support frame  114  in the second vertical position. 
     The support sled  112  is movable between the heat press machine  108  and the vacuum forming machine assembly  110 , and is configured to receive a sheet of thermoplastic material  120  therein to move the sheet of thermoplastic material  120  between the heat press machine  108  and the vacuum forming machine assembly  110 . The support sled  112  is positionable between a first sled position (shown in  FIG.  46   ) with the sheet of thermoplastic material positioned within the heat press machine  108 , and a second sled position (shown in  FIG.  45   ) with the sheet of thermoplastic material positioned above the vacuum forming machine assembly  110 . 
     In the illustrated embodiment, the support sled  112  includes a slide rail assembly  122  mounted to the support frame  106 , a base sled frame  124  mounted to the slide rail assembly  122 , and a cover frame  126  that is pivotably mounted to the base sled frame  124 . The cover frame  126  is positionable between an open position (shown in  FIG.  44   ) and a closed position (shown in  FIG.  45   . 
     The base sled frame  124  includes a frame member  128 , a support flange  130 , and a first sealing gasket  132  mounted on the support flange  130 . The frame member  128  defines a mold opening having a substantially rectangular cross-sectional shape. The mold opening is sized and shaped to receive the mold assembly  116  therein. The support flange  130  extends inwardly from the frame member  128  about a perimeter of the mold opening. 
     The support sled  112  is configured to support a sheet of thermoplastic material  120  between the first sealing gasket  132  of the base sled frame  124  and the cover frame  126  with the cover frame  126  in the closed position. 
     In the illustrated embodiment, the mold support frame  114  includes a second sealing gasket  134  positioned about a perimeter of the mold assembly  116 . The second sealing gasket  134  of the mold support frame  114  contacts the first sealing gasket  132  of the base sled frame  124  when the mold support frame  114  is moved to the second vertical position to facilitate a vacuum seal being created between the mold assembly  116  and the sheet of thermoplastic material  120 . 
     During operation, the vacuum pressure system  100  applies the vacuum pressure to the mold assembly  116  with the sheet of thermoplastic material  120  supported between the first sealing gasket  132  of the base sled frame  124  and the cover frame  126 , and with the second sealing gasket  134  of the mold support frame  114  in contact with the first sealing gasket  132  of the base sled frame  124 . 
     In some embodiments, the mold assembly  116  includes an array  136  of positive front cover mold assemblies  138 . The positive front cover mold assembly  138  includes a base member  140  and a cover member  142  extending outwardly from the base member  140 . The cover member  142  includes a plurality of sidewalls  144 ,  146 ,  148  extending between a first endwall  150  and an opposite second endwall  152 . The plurality of sidewalls includes a top sidewall  146  and a pair of opposing sidewalls  144 ,  148  extending outwardly from the top sidewall  146  towards the base member  140 . A pair of opposing raised members  154  are positioned adjacent each opposing sidewall  144 ,  148 . 
     The mold assembly  116  may also include an array  156  of positive back plate mold assemblies  158 . The positive back plate mold assembly  158  includes a base member  160  and a pair of opposing back plate mold members  162  that extend outwardly from the base member  160 . The pair of opposing back plate mold members  162  are spaced a distance apart and arranged in a mirrored relationship. In the illustrated embodiment, each back plate mold member  162  includes a planar outer surface  164  and a pair of raised positioning members  166  extending outwardly from the planar outer surface  164 . Each raised positioning member  166  includes a top endwall extending between a pair of sidewalls, a first endwall, and a second endwall opposite the first endwall. The second endwall extends from the top endwall towards the planar outer surface  164  at an oblique angle. 
     The CNC milling machine  104  includes a table  168 , a CNC milling assembly  170  mounted above the table  168 , a vacuum mold assembly  172  mounted on the table, and a vacuum pressure system  100  coupled to the vacuum mold assembly  172 . The vacuum mold assembly  172  includes a support plate  174  and a support mold  174  mounted to the support plate  174 . The support mold  174  includes a base member  176 , a plurality of positioning members  178  extending outwardly from the base member  176 , a plurality of openings  180  extending through the base member  176 , and a plurality of silicone gaskets  182  mounted on the base member  176 . The vacuum pressure system  100  is configured to apply a vacuum pressure to the vacuum mold assembly  172  through the plurality of openings  180  to facilitate mounting a hardened thermoplastic assembly to the support mold  174  during a milling operation. 
     In some embodiments, the system  100  may include a stitching mold assembly  184  that includes stitching base mold  186  and a stitching guide mold  188 . The stitching base mold  186  includes a recessed area  190  sized and shaped to receive the attachment member  70  therein, and one or more recessed channels  192  defined within the recessed area  190  that are sized and shaped to receive a corresponding locking tab  84  therein. The stitching guide mold  188  includes a stitching guide mold body including a plurality of stitching guide slots  194  that are defined along the stitching guide mold body. 
     In some embodiments, the present invention includes a molding assembly  116  for forming the ammunition magazine pouch  10 . The molding assembly  116  includes a plurality of molds to help form the different components of the ammunition magazine pouch  10 . The plurality of molds includes a back form cutout mold  158 , a back form full array mold  156 , a front form mold  138 , a brother pallet clamp mold  184 , a pallet clamp base mold  186 , and a pallet clamp top mold  188 . The plurality of molds are configured to help form the different components of the ammunition magazine pouch  10 . For instance, the back form cutout mold  158  is configured to form the back support member  26  by pressing the material over the mold and cutting each individual component of the ammunition magazine pouch  10 . The material used to make the ammunition magazine pouch  10  is passed under a specific tool and pressed against the plurality of molds to make each part. 
     In one embodiment, the back form cutout mold  158  is configured to make the back support member  26 . The back form full array mold  156  is configured to form a plurality of back support members. Similar to the back form cutout mold  158 , the front form mold  138  is configured to make a plurality of magazine front cover members  24  where the material used to make each magazine front cover member  24  is pressed or molded against the front form mold. 
     In another embodiment, the brother pallet claim mold, the pallet clamp base mold, and the pallet clamp top mold each include a plurality of holes. The plurality of holes are used as a template to drill the plurality of fastener openings for receiving the fastening assembly on both the magazine support member and the back plate assembly. For example, the pallet clamp base mold is placed on the finished flexible fastening member to layout where the plurality of openings need to be cut. Once each of the components of the ammunition magazine pouch  10  are formed each opening is sized and cut to receive a corresponding bolt set or snap set from the fastening assembly. 
       FIG.  63    is a flowchart illustrating a method  200  of manufacturing the tactical pouch  10 . The method includes a plurality of steps. Each method step may be performed independently of, or in combination with, other method steps. Portions of the methods may be performed by any one of, or any combination of, the components of the system  100 . 
     Method step  202  includes thermoforming a front cover member  24  from a first sheet of thermoplastic material  120 . For example, the first sheet of thermoplastic material  120  is placed within the support sled  112  with the support sled  112  in the second sled position and with the mold support frame  114  positioned in the first vertical positions such that the mold assembly  116  does not contact the sheet of thermoplastic material  120 . The first sheet of thermoplastic material  120  is placed onto the base sled frame  124  and supported by the support flange  130  and a first sealing gasket  132  about a perimeter of the about a perimeter of the first sheet of thermoplastic material  120 . The cover frame  126  is then moved to the closed position and secured with a locking clamp. The support sled  112  is then moved to the first sled position to position the first sheet of thermoplastic material  120  within the heat press machine  108 . 
     The heat press machine  108  is then operated to apply a heat treatment to the first sheet of thermoplastic material  120  to form a malleable thermoplastic sheet. For example, the heat press machine  108  is operated to apply the heat treatment at a predefined temperature and predefined pressure for a predefined period of time. At the completion of the heat treatment, the support sled  112  is then moved from the first sled position to the second sled position to position the malleable thermoplastic sheet over the mold assembly  116  including the array  136  of positive front cover mold assemblies  138 . The hydraulic lifting assembly  118  then operates to move the mold support frame  114  and mold assembly  116  from the first vertical position to the second vertical position to place the second sealing gasket  134  of the mold support frame  114  in contact with the first sealing gasket  132  of the base sled frame  124 . The vacuum pressure system  100  then applies a vacuum pressure to the malleable thermoplastic sheet to form a molded front cover assembly over the positive front cover mold assembly  138 . A fan is then operated to facilitate cooling the molded front cover assembly to form a hardened front cover assembly. 
     Once the hardened front cover assembly is formed, the vacuum pressure system  100  is operated to release the vacuum pressure, the hydraulic lifting assembly  118  is operated to move the mold support frame  114  and mold assembly  116  from the second vertical position to the first vertical position, and the hardened front cover assembly is removed from the support sled  112  and placed over the vacuum mold assembly  172  of the CNC milling machine  104 . The vacuum pressure system  100  of the CNC milling machine  104  is then operated to apply a vacuum pressure to the vacuum mold assembly  172  to facilitate mounting the hardened front cover assembly to the support mold  174 . The CNC milling machine  104  is then operated to mill excess material from the hardened front cover assembly and drill a plurality of fastener openings through the hardened front cover assembly for receiving the adjustable fastening members  60  of the tensioning assembly  28 . The milled hardened front cover assembly is then cut in half to form two front cover members  24 . 
     Method step  204  includes thermoforming a back plate member  26  from a second sheet of thermoplastic material  120 . Similar to the process of method step  202 , the second sheet of thermoplastic material  120  is placed within the support sled  112  with the support sled  112  in the second sled position and with the mold support frame  114  positioned in the first vertical position. The cover frame  126  is then moved to the closed position and the support sled  112  is moved to the first sled position to position the second sheet of thermoplastic material  120  within the heat press machine  108 . 
     The heat press machine  108  is then operated to apply a heat treatment to the second sheet of thermoplastic material  120  to form a second malleable thermoplastic sheet. At the completion of the heat treatment, the support sled  112  is then moved from the first sled position to the second sled position to position the second malleable thermoplastic sheet over the mold assembly  116  including the array  156  of positive back plate mold assemblies  158 . The hydraulic lifting assembly  118  then operates to move the mold support frame  114  and mold assembly  116  from the first vertical position to the second vertical position to position the malleable thermoplastic sheet onto a positive back plate mold assembly  158 . The vacuum pressure system  100  then applies a vacuum pressure to the malleable thermoplastic sheet to form a molded back plate assembly over the positive back plate mold assembly  158 , and a fan is operated to facilitate cooling the molded back plate assembly to form a hardened back plate assembly. 
     The hardened back plate assembly is then removed from the support sled  112  and placed over the vacuum mold assembly  172  of the CNC milling machine  104 . The vacuum pressure system  100  of the CNC milling machine  104  is then operated to apply a vacuum pressure to the vacuum mold assembly  172  to facilitate mounting the hardened back plate assembly to the support mold  174 . The CNC milling machine  104  is then operated to mill excess material from the hardened back plate assembly and drill a plurality of fastener openings and stud openings through the hardened front cover assembly for receiving the adjustable fastening members  60  of the tensioning assembly  28  and the attachment system  14 . The CNC milling machine  104  is also operated to etch the recessed stitching channels  86  along the front surface of the back plate member  26  for receiving the stitching for coupling the attachment system to the back plate member  26 . The milled hardened back plate assembly is then cut in half to form two back plate members  26 . 
     Method step  206  includes stitching the back plate member  26  to an attachment system  14 . For example, the attachment system  14  is positioned onto the stitching base mold  186  with the locking tabs  84  positioned in the recessed channels  192  and the attachment member  70  positioned over the locking tabs  84  within the recessed area  190 . The back plate member  26  is then positioned onto the attachment system  14  within the recessed area  190 . The stitching guide mold  188  is then positioned onto the back plate member  26 , and a stitching machine is operated to apply stitching to the attachment system  14  and the back plate member  26  along the plurality of stitching guide slots  194 . The recessed stitching channels  86  of the back plate member  26  correspond to the stitching guide slots  194  to facilitate reducing stitching protruding into the magazine chamber  16 . The snap button assembly  76  is then coupled to the attachment member  70  and the back plate member  26 . 
     Method step  208  includes coupling the front cover member  24  to the back plate member  26  to define the magazine chamber  16  therebetween and extending between the open top end  18  and the closed bottom end  20 . For example, the front cover member  24  may be coupled to the back plate member  26  with an adhesive such that the support flange  36  is adhered to the front surface of the back plate member  26 . 
     Method step  210  includes coupling the tensioning assembly  28  to the front cover member  24  and the back plate member  26  to form the tactical pouch  10 . In some embodiments, press-fit threaded inserts are mounted to the back plate member  26  before adhesive is applied and the front cover member  24  is coupled to the back plate member  26 . The fastening screws are then inserted through the fastener openings and into the press-fit threaded inserts. 
     Obviously, many modifications and variations of the present invention are possible in light of the above teachings. The invention may be practiced otherwise than as specifically described within the scope of the appended claims. 
     Although specific features of various embodiments of the disclosure may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the disclosure, any feature of a drawing or other embodiment may be referenced and/or claimed in combination with any feature of any other drawing or embodiment. 
     This written description uses examples to describe embodiments of the disclosure and also to enable any person skilled in the art to practice the embodiments, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.