ASX Announcement – XTclave(TM) Successfully Recommissioned

Key highlights:

• The XTclave™ system has been successfully recommissioned at HighCom’s Columbus, Ohio, facility
• System capacity has been significantly enhanced, with output now doubled
• U.S. based personnel are currently undergoing comprehensive training in system operations and processes
• HighCom continues to collaborate closely with the U.S. Department of Defense and other government entities on the development of advanced product solutions utilising XTclave™ technology
• Production of existing product lines is scheduled to recommence in Q1 FY26
• A new product line is under development, with commercial release targeted for the end of Q2 FY26

HighCom Limited (ASX: HCL) (HighCom or the Company) is pleased to announce the successful
re-commissioning of the XTclave™ system—HighCom’s proprietary ultra-high isostatic pressure consolidation technology, purpose-built for advanced composite manufacturing. With the system now fully operational, the Company is focused on completing training for U.S.-based personnel and finalising the integration of ancillary equipement to support optimised functionality and production efficiency. The successful recommissioning signifies the completion of an 18-month strategic endeavour, establishing a robust foundation for the Company to initiate production of a new generation of globally competitive and highly sought-after products, while enhancing operational efficiencies and contributing to improved profit margins.

During Q3 FY24, HighCom successfully relocated the XTclave™ system from Australia to its manufacturing facility in Columbus, Ohio. As part of the reassembly process, significant enhancements were implemented, including the integration of a new water-based cooling system, which replaced the previous air-based system, to ensure optimal performance under Ohio’s climate conditions. Additionally, a larger pressure vessel was constructed, doubling the original capacity and achieving certification from the American Society of Mechanical Engineers (ASME). This upgraded vessel enables the XTclave™ to complete a minimum of three production cycles per shift, with an estimated annual output of up to 40,000 ballistic plates. The expanded capacity and versatility of the new pressure vessel now allow for the processing of a broader range of products, including ballistic plates, helmets, shields, complex geometries, and specialized applications such as aviation and vehicle armor.

The XTclave™ system is a proven and advanced manufacturing technology designed to produce ultra-lightweight, thin, and high-strength ballistic products. These products are particularly well-suited for use by military forces, government agencies, and specialised law enforcement units. XTclave™ offers a significant competitive advantage in the U.S. market through its capability to form complex contours in a single processing step, coupled with superior material consolidation. This results in enhanced structural integrity and reduced weight across a range of ballistic solutions. All products manufactured using XTclave™ technology will be compliant with the U.S. Berry Amendment, thereby enabling HighCom to actively pursue sales and tender opportunities with the U.S. Department of Defense.

HighCom currently maintains a Cooperative Research and Development Agreement (CRADA) with the U.S. Army Development Command and is actively engaged in broader collaborative efforts within the U.S. Department of Defense. These initiatives focus on the research and development of selected ballistic products incorporating XTclave™ technology. Through close cooperation with the U.S. military, HighCom is positioned to secure ongoing research and development funding. This strategic engagement not only supports the advancement of innovative defense solutions but also enables HighCom to participate in future tender processes, thereby enhancing its ability to compete for significant government contracts.

HighCom’s initial commercial focus for XTclave™ is directed toward the development of a new ‘Superior’ range of ultra-lightweight ballistic plates—both with and without ceramic components—including female-form body armor and rifle-rated helmets. These advanced products will undergo a comprehensive refinement process over the coming months.

To uphold the highest standards of quality and performance, all new products will undergo rigorous independent testing by accredited laboratories. This testing is intended to evaluate and validate the ballistic integrity of each product prior to market release or submission for National Institute of Justice (NIJ) certification.

It is anticipated that customer orders for the new product range will commence in the second quarter of fiscal year 2026 (Q2 FY26), with initial deliveries expected by the end of that quarter. Concurrently, HighCom will recommence production of select XTclave™ product lines — previously manufactured in Adelaide, South Australia — for commercial availability in the first quarter of fiscal year 2026 (Q1 FY26).

In addition to the upcoming production of HighCom’s cutting-edge ‘Superior’ range using XTclave™ technology, the Company will maintain production at the Columbus facility of its trusted ‘Classic’ range utilising commercial oven technology. Furthermore, the Company will continue manufacturing its ‘Enhanced’ mid-range plates through axial pressing, ensuring a comprehensive portfolio that meets the diverse protection needs of its global customers.
This strategic approach reinforces HighCom’s commitment to innovation, reliability, and excellence in personal protection solutions.

HighCom’s Chief Executive Officer, Mr Todd Ashurst, commented:
“We are proud to announce the successful re-commissioning of our proprietary XTclave™ system at HighCom’s Columbus, Ohio, facility. This milestone marks a significant step forward in our commitment to innovation, operational excellence, and delivering world-class ballistic protection solutions. This achievement is more than a technical upgrade; it is a strategic enabler. It allows us to accelerate the development of next-generation ballistic products, strengthen our collaboration with the U.S. Department of Defense, and pursue major contract opportunities through Berry Amendment-compliant manufacturing. Thank you to our dedicated team who made this possible. We are excited about the future and confident that XTclave™ will play a pivotal role in HighCom’s continued growth and leadership in advanced armor solutions.”

This ASX announcement has been authorised for release by the Board.