How to Store and Reuse Ballistic Gel for Testing

Before getting into storage and reuse, it's important to understand that not all ballistics gel is the same and that difference matters more than most people realize.

For decades, most law enforcement and ammunition tests have relied on organic or traditional gelatin, a temperature-sensitive mixture made from animal collagen and water. Often referred to as "10% ballistic gel," this material forms the basis of FBI handgun testing standards and must be kept at approximately 39.2 degrees Fahrenheit to remain calibrated, or valid. If organic ballistics gel warms outside that range, its consistency and test results can change.

Clear Ballistics products are made from 100% synthetic, clear, and reusable gel substitute, engineered for clarity, durability, and repeatable testing. Unlike organic gel, synthetic gel does not need to be mixed, refrigerated, or discarded after a single use, and its optical clarity allows shooters, instructors, and engineers to clearly see bullet expansion and wound tracks in real time.

Why Storage and Reuse Depend on the Type of Gel

How to Store Clear Ballistics Gel

Proper storage helps extend the life of your synthetic gel and keeps it ready for future testing.

Short Term Storage

Keep the gel block in a clean container or wrap in plastic to prevent dust and debris. We recommend storing at room temperature in a dry area and avoiding direct sunlight over a long period of time. Synthetic gel does not require refrigeration.

Long Term Storage

Clean the gel block after use to remove debris. Store it in a sealed container or heavy plastic bag and place it in a dry environment away from heat sources. When stored properly, Clear Ballistics gel can be kept for years without degrading.

Reusing Clear Ballistics Gel for Testing

Clear Ballistics gel is designed to be remelted and reused many times. This makes it a practical choice for shooters, manufacturers, and trainers who need reliable testing without buying new blocks after every session. The process is straightforward and can be done at home with basic equipment.

Here's how the reuse process works:

Now that you've seen how simple the process is, it's worth looking at why reusing ballistic gel matters in the first place.

Why Reuse Matters

Reusing ballistic gel offers more than just convenience. It has lasting advantages for anyone running multiple tests.

Reason #1: Cost Savings

Every block can be melted down and recast up to ten times. This reduces replacement costs and makes testing more affordable over the long term.

Reason #2: Sustainability

Instead of throwing away used blocks, remelting cuts down on waste. This is especially important for high-volume testers who cycle through gel often.

Reason #3: Consistent Results

Synthetic gel maintains its calibration through multiple uses. Each recast block reacts the same way, so you can compare results across tests with confidence.

Of course, to get those benefits, you also need to avoid the most common mistakes during the remelting process.

What to Avoid

To get the most life and accuracy out of each block, a few common mistakes should be avoided.

Mistake #1: Extreme Heat

Temperatures above 280°F can scorch or discolor the gel. Slow, steady heating preserves its clarity and performance.

Mistake #2: Contamination

Residue from bullets, powder, or dirt can become trapped inside during remelting. Always filter carefully to keep the gel clear and usable.

Mistake #3: Poor Molds

Dirty or damaged molds may cause air bubbles or uneven surfaces. A smooth, clean mold produces a block that is easier to test and inspect.

Handled correctly, these precautions make reusing ballistic gel not only practical but also dependable for repeated, accurate testing.

Reusing Clear Ballistics gel is a simple cycle of preparation, melting, and recasting. Done correctly, it delivers the same accuracy test after test while saving money and reducing waste. This repeatability is what makes Clear Ballistics gel a trusted tool for serious testing.