GECO Express – How Our Ultra-Fast Hunting Bullet Is Made

Dear GECO fan,

Today, our product development team is sharing exclusive insights into the production of the ultra-fast GECO Express bullet. Join us on a journey through the meticulous process behind its creation.

Lead Wire & Cup

Before the bullet itself is manufactured, the two main components—jacket and core—must be prepared. First, hard lead ingots are melted down and partially reshaped into cylindrical rods. After cooling, these rods are cut to length and drawn into lead wire using a heated die.

The lead wire is then wound onto spools, ready for the next stage. It will later be pressed into bullet cores, using specific lead alloys depending on the bullet type. In a separate process, bullet cups are pressed, which will later be drawn into the jacket. Due to varying designs and calibers, this step involves significant production complexity.

The in-house production of all components is a crucial part of our quality assurance and ensures we meet GECO’s high manufacturing standards.

Jacket Drawing & Core Pressing

The GECO Express consists of a lead core and a tombac jacket. The preformed bullet cup undergoes a two-stage deep drawing process.

In the first stage, an initial deep draw is performed. In the second stage, the jacket is brought to its final length and wall thickness. During this process, slight irregularities may appear at the jacket mouth—so it’s drawn slightly longer than needed. Excess material is trimmed off afterward.

The jacket is then cleaned, while a separate machine cuts the lead core to precise dimensions, pre-presses, and cleans it. Now both parts are ready for assembly.

Bullet Assembly

In several steps, the core is inserted, the base and ogive are formed, and the bullet is shaped into its final geometry. The final step is the insertion of the ballistic polymer tip.

Each production batch is subjected to function testing, ensuring the bullet performs reliably during later cartridge assembly and use.

A standout feature of GECO Express is the slightly tapered jacket toward the ogive, allowing for very fast expansion upon impact and resulting in high immediate effect—even at longer ranges. Its streamlined design and ballistic tip deliver exceptional precision and a flat trajectory.

GECO Express is a top-performing choice for any hunting scenario—and truly shines when accuracy at long distances is key.