The Fusion Tipped Advantage

It all started with the desire to create a deer hunting cartridge that combined the best qualities of traditional hunting bullets with the advantages of modern ones. But few could have predicted what would happen after Federal introduced Fusion in 2005. Fueled by its unique bullet construction and Federal’s precise, consistent loading, the Fusion line became an instant success. Soon, Fusion filled out a full line of ammunition featuring bonded bullets specifically engineered for deer hunting, offering excellent weight retention, expansion and accuracy.

But the ammunition evolution didn’t stop. Now, this time-tested technology is expanding yet again to with an all-new lineup: Fusion Tipped.

A Proven Blueprint

The fundamental concept behind all Fusion loads is the use of a specialized bullet with an electrochemically bonded core. The plated bullet design has an extremely concentric layer of copper around the lead core, which makes Fusion one of the more accurate hunting bullets on the market.

The specialized bonding process ensures the bullet’s jacket and core remain secured together, delivering superior weight retention for deeper penetration upon impact. This innovation is a significant upgrade from traditional cup-and-core bullets—projectiles manufactured by mechanically pressing a cupped metal jacket on to a lead core—which tend to experience core separation upon impact. Separation of a bullet’s jacket and core can reduce terminal performance and penetration depth, resulting in less chance of pass-through.

“Following its initial release, Fusion quickly gained a reputation for its exceptional performance and reliability,” says Eric Miller, Federal’s Centerfire Product Line Manager. “Since then, we have expanded Fusion into a large list of calibers and bullet weights, now totaling more than 50 product offerings across three different product families. This has allowed hunters and shooters to experience the benefits of bonded-core technology across a broad spectrum of firearms and game species.”

In addition to its expansions in terms of calibers, bullet weights and intended uses, Fusion also saw advancements in bullet design and manufacturing processes. Over the years, Federal continued to refine the Fusion bullet, optimizing its ballistic coefficients and terminal performance to ensure consistent accuracy and reliable expansion at various distances and velocities.

Poly-Tipped Performance

Already accurate, lethal and proven by nearly 20 seasons in the deer woods, the Fusion bullet design was ready for its next evolution with the addition of a polymer tip.

“Rifle ammunition featuring polymer tips is nothing new. Yet it has revolutionized the shooting industry with its innovative design and exceptional performance,” says Jake Burns, Federal’s Centerfire Rifle Engineering Manager. “Polymer tipped ammunition has become a popular choice among hunters, competitive target shooters, and law enforcement professionals.”

One of the key features of polymer-tipped rifle ammunition is its ability to deliver enhanced ballistic performance. The streamlined design of the polymer tip reduces drag and improves the ballistic coefficient of the bullet, resulting in flatter trajectories, increased accuracy and more retained energy over longer distances. This feature is particularly advantageous for hunters who require consistent accuracy and reliable performance at extended ranges.

“The aerodynamic properties of polymer-tipped rifle ammunition contribute to improved flight characteristics and stability. The sleek profile of the bullet, combined with the polymer tip, reduces air resistance, and minimizes the effects of crosswinds, resulting in more predictable and stable trajectories,” explains Burns. “This feature is especially valuable for long-range shooting, where maintaining stability and accuracy over varying environmental conditions is essential.”

Beyond Just Deer Camp

For its initial launch, Fusion Tipped will be offered in nine loads, including both old favorites and new cartridges like 6.5 PRC, 6.5 Creedmoor, 270 Win., 7mm Rem. Mag., 7mm PRC, 308 Win., 30-06 Sprg. and 300 Win. Mag.

One of the more interesting loads in the lineup is the 300 Blackout. Federal customers had long asked for a terminal subsonic round for the cartridge, so development of this load actually began before work kicked off on the broader Fusion Tipped line. However, it quickly became apparent a tipped design would be needed for optimal performance.

With the initiation of Fusion Tipped, Federal's engineers found a perfect path to the ultimate 300 Blackout hunting round. In addition to the attributes shared by all Fusion Tipped loads, the Terminal Subsonic 300 Blackout is optimized for cycling and overall performance in the MSR platform.

And with such a broad lineup and versatility, Fusion Tipped is poised to pick up where original Fusion left off, offering accuracy and lethality far beyond the confines of the deer camps where the whole story began.