At SHOT Show 2026, Classic Firearms stops by the US Palm booth to focus on the new CAT4 rifle and the upcoming 115 pistol. Sean explains that the goal was to build an AR-15 with the features and performance typically found on rifles in the $2,500 to $3,000 range, but at a more attainable MSRP of about $1,299. The team behind the project includes engineers with extensive industry experience who wanted to create something distinct in a crowded AR-15 market. Rather than releasing a basic rifle at a good price, they aimed to integrate higher-end features and thoughtful engineering into a complete package while keeping it accessible on cost.
Sean highlights that the CAT4 is fully ambidextrous. It includes a 45-degree ambidextrous safety, a right-side bolt catch and release, a left-side magazine release, and an in-house designed ambidextrous charging handle that remains compatible with standard AR-15 platforms. Particular attention was paid to ergonomics, such as finger reach and control placement, to suit users who run rifles hard. At the rear of the charging handle, a raised surface is incorporated to help with gas mitigation when the rifle is used with a suppressor. Sean notes that there are 16 patents pending on the rifle’s construction, reflecting the number of small design details built into the platform.
The discussion moves to internal components, especially the bolt carrier group. Sean explains that both the bolt and the barrel extension use a DLC (diamond-like carbon) coating. This coating increases lubricity, allowing the rifle to run more smoothly in drier conditions, and also enhances durability. In testing, rifles surpassed 12,000 rounds without a single bolt lug shearing, which Sean contrasts with typical mil-spec bolts where lug failures often begin to appear around 6,000 rounds. Those results were important because the design team drew on experience with military and law enforcement requirements, where rifles must function reliably under demanding conditions and extended use.
Sean then explains the upper receiver design, which US Palm calls the monolock system. The upper receiver is extended so that it becomes the mating surface for the handguard, creating a rigid interface. This approach delivers the performance benefits associated with monolithic uppers while preserving AR-15 modularity. The handguard is secured with two bolts and slides off for easy changes, and US Palm plans to offer additional handguard options in lighter weights and different lengths. The monolock system is part of a broader effort to accurize the rifle. Both the barrel nut and barrel extension use a conical mating surface, similar to how a lug nut centers, allowing the barrel to self-center in production and provide consistency and accuracy typically associated with custom gunsmith work.
When asked about barrel materials and configuration, Sean states that the CAT4 ships with a nitrided cold hammer forged barrel, a feature the team considered important for longevity and performance. Despite the proprietary nature of the monolock handguard interface, the system accepts any mil-spec AR-15 barrel, so users can install their preferred barrel brands if desired. US Palm uses its own low-profile gas block on a standard 0.750 journal, making it familiar and serviceable. The CAT4 rifle uses a mid-length gas system, while the 115 pistol uses a carbine-length gas system. The barrel has a 1:7 twist rate, aligning it with common AR-15 configurations while supporting a range of bullet weights.
Attention turns to the distinctive muzzle device, which US Palm calls the hurricane flash hider. Sean describes it as a hybrid flash hider and compensator. It has two ports that contribute to recoil mitigation and help the rifle return to target more consistently during strings of fire. The device is 3D printed, not as a prototype but because its complex internal and external geometry cannot be produced by conventional machining. Engineers with suppressor design experience applied flow dynamics to the layout. The tines twist at the same rate as the barrel, and internal ridging helps break up gases as the bullet exits. According to Sean, this results in very effective flash reduction while also providing the control benefits typically associated with a compensator.
As the conversation wraps up, the host mentions wanting to shoot the CAT4, including with a suppressor, to evaluate the charging handle’s gas mitigation features in real use. Sean notes that US Palm has also launched a line of suppressors, allowing users to pair the CAT4 with matching US Palm cans. The segment closes with appreciation for the engineering depth and attention to detail that went into the rifle, especially for a first AR-15 entry from the brand. Viewers are encouraged to take a closer look at US Palm and the CAT4 platform, with the expectation of further testing and range time to explore its performance in more detail.
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