Patent ID: 8584589

Claim:
A method for forming a dehydrated, pulp-based projectile, the method comprising acts of: dipping a mesh mold into a container filled with a pulp solution; applying a vacuum to the mesh mold to draw pulp material from the pulp solution into depressions in the mesh mold; removing the mesh mold from the container, leaving a pulp-slush coating the mesh mold; applying a vacuum to the mesh mold to draw liquid from the pulp-slush, forming a semi-dehydrated pulp plate; removing the semi-dehydrated pulp plate from the mesh mold; dehydrating the semi-dehydrated pulp plate to form a fully dehydrated pulp plate; and die stamping the fully dehydrated pulp plate to shear a plurality of projectiles from the fully dehydrated pulp plate, resulting in a plurality of projectiles and a remaining pulp plate.