Technical Solutions Group had been a defense company in the US that was involved in a range of products, including mine-resistant vehicles based on South African designs.

In early 2004 the United States Marine Corps (USMC) visited Force Protection and, having seen a photo-montage of a new design of MRAP on a company brochure, asked if it could be produced and delivered within 6 months of an order for operations in Iraq.

The photo was a still only concept image, but a senior person in the company offered to design, develop and build a new vehicle, that met the USMC requirement, within the deadline of 6 months.

The structure of the hull around the commander and driver was considerably strengthened to add to the torsional stiffness of the vehicle, and the hull-sides were redesigned to provide additional space for troops or equipment.

A full armor-upgrade pack was offered from the start, and the design specifically allowed for the addition of advanced armor systems such as the British chobham type.

After further talks, the need for levels of mobility covering beach-operations resulted in a suggestion that the 4x4 design should be augmented by a 6x6 version, which would also have a larger payload and volume in the cargo area.

Subsequent meetings with the Army also led to changes in some of the major sub-systems to ensure even greater commonality with in-service equipment in order to ease training and support.

Later, and to satisfy the needs of politicians to show that they were committed to the war in Iraq, the program was again changed to MRAP, at which time other companies became involved in the design and supply of similar vehicles, most of which were based in part, or entirely, upon the Cougar.

[9] US Defense Secretary Robert Gates demanded that the vehicles be ordered in larger numbers after the Marines reported in 2004 that no troops had died in more than 300 IED attacks on Cougars.

This is in line with British Army doctrine concerning the role of the APC/MICV, specifically that it is to carry troops under protection to the objective and give firepower support when they have disembarked.

[47][48] As of November 2008, the British Army has ordered over 400 Cougar vehicles for deployment in Iraq and Afghanistan following a series of Urgent Operational Requirements (UORs).

In October 2007, Gordon Brown announced a further 140 Mastiffs and 157 new Cougar 4x4 variants, named Ridgback were being ordered to protect troops from mines and roadside bombs.