Ultimate Guide to Body Armor

When it comes to personal safety and protection Tacticon Armament stands at the forefront of innovation and reliability. With nearly a decade of experience in crafting premium body armor solutions, we’ve earned our reputation as an industry leader. Our commitment to excellence extends beyond a mere product – it’s a dedication to your peace of mind.

At Tacticon, we understand the need for effective, high-quality body armor. Whether you’re in law enforcement or a civilian, we firmly believe that everyone deserves the best protective equipment. That’s why we’ve meticulously developed a range of NIJ certified body armor models, from steel to cutting-edge ceramic and UHMWPE options.

We crafted The Ultimate Guide To Body Armor to help empower you with the essential knowledge necessary for personal safety decision making. Join us in our comprehensive overview of crucial body armor gear, exploring various armor types, ideal plate materials, cut types, accessories, and more. At Tacticon, we prioritize safety and strive to provide effective, quality armor accessible to all budget levels.

Brief History of Body Armor

Body armor has been used for centuries to shield individuals from threats like knives, arrows, and bullets. Body armor is specialized protective clothing designed to mitigate the impact of various projectiles and threats, reducing the risk of injury or fatality to the wearer. It serves as a critical barrier against a range of potential dangers, including bullets, edged weapons, and explosive fragments.

We’ll start by tracing the historical journey of body armor, examining its evolution, significance, and varied uses over the years. From its origins to its contemporary applications, we’ll uncover the intriguing history of body armor and bulletproof vests.

Ancient Beginnings: The roots of body armor can be traced back thousands of years to ancient civilizations. In these early times, warriors relied on inventive yet rudimentary forms of protection. Heavy wool and fabrics were used to create padded garments that offered some defense against slashing attacks and projectiles.

Bronze and Steel Era: As human conflict evolved, so did the need for more sturdy protection. The Bronze Age introduced the use of metal armor, providing enhanced defense against edged weapons. Later, during the Middle Ages, steel armor became synonymous with knights and chivalry. These suits of armor were intricate and remarkably effective against swords, spears, and arrows.

Revolutionary Materials: The Industrial Revolution brought about significant advancements in materials and manufacturing processes. This era witnessed the emergence of new materials like aramid fibers and ceramics, which revolutionized body armor. Aramid fibers have an exceptional strength to weight ratio and became the foundation for soft body armor like bulletproof vests.

Modern Innovations: In the 20th century body armor underwent a profound transformation. Ballistic resistant materials like Kevlar and UHMWPE (Ultra-High-Molecular-Weight Polyethylene) became the standard for both soft and hard body armor. These lightweight yet incredibly strong materials made it possible to create highly effective protection against firearms.

The origins of modern body armor, including materials like Ultra High Molecular Weight Polyethylene (UHMWPE) can be attributed to several pioneering individuals. German chemist Hans von Pechmann played a key role in the development of UHMWPE while initially working on creating gasoline additives. The evolution of body armor includes advancements such as ceramic rifle plates, and an improved iteration of armor used by Vietnam aircrews to protect them from small arms fire.

Further, Stephanie Kwolek discovered Kevlar at DuPont Labs while originally focused on enhancing tire durability and fuel efficiency. Kevlar has left an indelible mark on the foundation of contemporary body armor. These inventors and discoveries have significantly contributed to the state-of-the-art body armor we use today.

Contemporary Applications: Today, body armor finds applications far beyond the battlefield, and is worn by military, law enforcement, security, and civilians alike. 

In addition to its use in the field, body armor materials have found applications in medical devices, technology, and various industries where impact protection is a concern. Regardless of the material used body armor is based on the same principles. When struck, the armor materials absorb the energy of a projectile and utilize their material structure to spread the force across a larger surface area, reducing both the felt energy, and halting the velocity of the projectile.

On a scientific level this process varies slightly based on materials, however the general principle remains the same. If you’re eager to dive deeper in the science, explore our How Does Body Armor Work article to uncover armors intriguing physics, and much more.

Types of Body Armor

Now that we’ve discussed the purpose and history of body armor, let’s examine the different types of body armor that have been developed to cater to users’ varying needs. These armor types come with distinct features and levels of protection, allowing you to select armor that suits your specific needs and situation. There’s no universal solution; armor isn’t one size fits all. While some types may work fine in certain situations, they might not be optimal. Therefore, the selection of armor should prioritize what’s most suitable for the circumstances you’re most likely to encounter. Let’s review the common types of body armor available today.

Soft Body Armor

The most ubiquitous form of body armor is what is referred to as a “Bulletproof vest.” This is soft body armor, which is usually worn underneath clothing. Soft body armor conforms to the body, and is flexible, meaning armor of this form can be made to cover more of the body since it will flex and is light weight. Soft body armor is pistol rated armor, generally made of UHMWPE or Kevlar which will stop most pistol and many shotgun rounds. This is worn by law enforcement and many others because the majority of shootings involve a pistol rather than a rifle.

Hard Body Armor

Hard body armor is focused on stopping rifle threats. Soft armor is not able to stop rifle rounds due to the sheer velocity of rifle rounds and the amount of energy they transfer upon impact. There are various materials used to make rifle plates, such as steel, ceramic composite, and UHMWPE, each having their own benefits and drawbacks. There are various sizes, and patterns for hard body armor plates, but due to their rigidity and weight, they cover less surface area than soft armor.

Stab/Spike Resistant Armor

As mentioned, not all body armor is primarily concerned with stopping bullets. Stab proof vests and spike resistant armor are made to protect the wearer from sharp object attacks. This is often seen in correctional settings and civilian settings to protect from knives, shivs, etc. Depending on the armor specifics it may also be bullet resistant, but not necessarily.  

Multithreat Armor

Multi-threat armor is a term for armor that incorporates a design to stop more than one specific threat. For example, most law enforcement uses multi-threat armor rated to protect from common handguns, shotguns, and edged weapons. The idea is to protect against as many likely threats as possible while adding minimal weight.

Not all multi-threat armor offers the same range and level of protection. With any type of armor, there will be tradeoffs. It is important to look at the most likely circumstances of use as a guiding factor and make your selection based on your specific needs. 

My rule of thumb is there are three primary tradeoffs, protection level, weight, and price. You can generally get two out of three. Armor that is light weight with a high level of protection will come at a higher price. Armor that is highly protective and less expensive will be heavier, etc. 

Types of Body Armor Vests

Let’s move on to discussing the various types of body armor vests. To begin, there are two catch all terms that have become synonymous in popular culture and media that we need to talk about; bulletproof vests vs body armor. The distinction between the terms is extremely important.

Body armor is really any sort of worn protective equipment, or ballistic protective equipment. Therefore a bulletproof vest is body armor, however, bulletproof vests is actually a specific term for soft body armor worn under clothes by law enforcement. Similarly, another term you should know is ‘plate carriers’.

Plate carriers are the garment that holds the ballistic armor plates, as they (plate carriers) do not provide protection by themselves. This may seem a bit confusing right now, but don’t worry as we will clear up everything throughout this body armor guide.

Concealed Body Armor & Tactical Body Armor

The distinctions in body armor vests become more prevalent when we begin discussing concealed body armor vs tactical body armor. Concealed body armor is most commonly a bulletproof vest, designed to blend in and not draw attention.

Tactical body armor takes a different approach and is worn as the outermost layer of the body. Tactical vests generally incorporate pouches and gear storage methods or have the ability to add pouches to carry more gear. The reasons someone may choose concealed armor is somewhat clear, they wish to blend in.

Tactical body armor is generally worn in situations like a deployed environment where carrying gear, being identifiable, or being able to add external armor is more desirable than trying to blend in.

If you are interested in a more in-depth comparison we have all the details you need in our concealed body armor vs tactical body armor overview.  

Female-Specific Body Armor Vests

Female body armor entered the spotlight as more and more women joined the military and law enforcement agencies. Female-specific vests and carriers are designed to fit the female body. This female-specific armor is manufactured to have different dimensions than the majority of plates on the market. Female body armor is generally .5” – 1” narrower than standard 10” x 12” plate.

This slight change in dimension accounts for the necessary curves that allow a much better (and proper) fit for the female form. Proper fitting body armor is important, if the armor is not snug and fits improperly it will slide, leaving vital areas exposed. 

If body armor is not tight to the body it will move under inertia, which can throw off balance while moving. This is not to say armor can’t be unisex, it really comes down to individual fit. The advantages of properly fitting armor are tremendous, and while armor is not a one-size-fits-all, the closer you can get to perfect fitment the better. Within the same armor model, there should not be a difference in protective abilities between single-curve, multi-curve, and female-curved armor, and there are really no downsides to selecting the plate that fits you best. 

Plate carriers

Plate carriers are the most popular and abundant type of vest. They are designed as modular tactical vests that can be adapted to a user’s needs for that time. They are most commonly worn overtly, although there are some low profile plate carriers that are designed to conceal thin rifle plates, but this is less common.

Most plate carriers are equipped with MOLLE, a universal method for attaching gear. This means the plate carrier itself serves as the foundation for the overall load out. Plate carriers come in many shapes and sizes, from concealable, to minimalist, and heavy load-bearing carriers built to support larger loadouts. 

Plate carriers utilize a variety of different cummerbunds from skeletal which allows for more airflow, to load-bearing cummerbunds for mounting accessories. They are generally designed for 10”x12” plates, and some will also accommodate 11”x14” plates. Further, certain carriers have built-in side plate accommodations, whereas others need side plate pouches to accommodate side armor.

The benefit of a plate carrier over soft armor carriers comes largely from the MOLLE system, which allows the end user to attach and mount pouches, radios, and much more. The customization allows the user to manage weight distribution, add side plates, and swap out the protective plates depending on their needs. 

Backpacks

Backpack armor has become very popular in recent years due to the unfortunate rise in school and workplace shootings. Plates designed to fit into backpacks can be added to almost any backpack’s main compartment, especially if there is a laptop area. These plates are generally flat and rectangular in nature to give the best fit and maximize coverage.

Some companies do make specialized backpacks that have the armor already sewn inside the backpack. However this increases the overall price due to labor, and the added cost of the backpack. The benefit of Tacticon backpack armor is its ability to be transferred from one backpack to another, without requiring a specialized backpack. 

Backpack armor is available in either level IIIA pistol-rated backpack armor, or various levels of rifle-rated backpack armor, depending on the needs of the wearer. 

Body Armor Threat Levels

The National Institute of Justice (NIJ) is the research, development, and evaluation agency of the larger Department of Justice. 

The NIJ plays the central role in the development, testing, and certification process or body armor in the United States. Ultimately, they are responsible for establishing and maintaining performance standards and testing protocols that manufacturers of body armor must adhere to. Calling body armor “Bulletproof” perpetuates the misnomer that all armor is equally protective against any threat. In reality body armor is bullet resistant rather than bulletproof, and this is where the NIJ comes in.

In order for body armor to be labeled as NIJ Certified Body Armor, manufacturers must submit their armor products to the NIJ for rigorous testing according to NIJ standards to determine if the armor meets the required performance criteria. Even after certification, ongoing FIT tests are required to ensure the armor continues to meet NIJ standards over time.

Under the current 01.01.06 armor levels standard the NIJ has 5 levels:  Level IIA, Level II, Level IIIA, Level III, and Level IV, which indicate the armor’s ability to stop specific types of bullets. These standards ensure that body armor provides reliable protection to the individuals who rely on them for their safety.

However, the updated 01.01.07 standards are expected to be released in the near future, which includes new threats that have not been a part of previous certification requirements. The first important distinction is that levels IIA, II, and IIIA are rated for handgun protection, whereas Levels III and IV are rated for rifle protection. The best body armor is determined by the anticipated threats, as each level comes with inherent tradeoffs.

Let’s explore the existing body armor levels under the 01.01.06 standards.

Level IIA

Level IIA body armor is currently the lowest level available, designed to stop 9mm and 40 S&W FMJ rounds. The benefit of level IIA is that it is incredibly light and incredibly thin. Of course, the tradeoffs are very limited protection and greater energy transfer to the wearer.

Level II

Level II is similar to level IIA with a slight increase in weight and thickness. It also adds additional protection against 357 Magnum JSP rounds. Levels II and IIA can be difficult to find as level IIIA is the more common pistol rated configuration.

Level IIIA

Level IIIA body armor is premier pistol rated armor. It tends to be slightly heavier, and slightly thicker than lower levels, but the increase is minimal, and the added protection is significant. Level IIIA body armor is tested against 357 Sig at velocities of 1470 FPS, and 44 Magnum hollow points at speeds of 1430 FPS. Put simply, Level IIIA is rated to stop all common handgun rounds and is commonly available in both soft body armor and hard armor plates.

Level III

Level III body armor is entry level rifle protection as rated by the NIJ. To become certified, Level III must stop 6 shots of 7.62×51 (M80 ball), similar to .308, with less than 44mm of back face deformation from the first two rounds. All three primary materials (steel, UHMWPE, and ceramic composite) can be used to make Level III body armor. As such, Level III has a wide weight range, from about 2.95 lb (UHMWPE) to 8 lb (Steel), and a wide price range ($100-$600+).

The downside of Level III is that it is only tested with 7.62×51, which does not take into account higher velocity rounds such as M193 5.56 and specialized rounds such as M855 5.56 which has a small steel penetrating tip. Certain steel plates have failed to stop M193 rounds; similarly, UHMWPE plates are defeated by M855 and other rounds that incorporate steel or other hard metals.

Level III+

Level III+ body armor is not an NIJ level, rather it is an industry designation used to denote that the plate has been tested to level III and stops the aforementioned rounds level III is not tested for.

At its core, these are level III plates that were designed to outperform level III standards and stop 5.56 threats. The most common level III+ plates are steel, but there are also many offerings in ceramic as well. The weight of ceramic plates in this category will often range from 4-6 pounds per plate, and cost anywhere between $200-$800+ per plate. Some Level III+ body armor plates will also be designed to stop certain armor penetrating rounds, however, check with the manufacturer regarding that specific model.

Level IV

Level IV is the ultimate protection featuring the highest rating NIJ bestows upon body armor. The test caliber for this level is one shot from armor piercing M2AP 30-06 from 45 feet at a zero-degree angle. M2AP is a very difficult round to stop, especially from that distance.

Level IV body armor is then shot with a “Lesser threat” to check the plate’s integrity. Ceramic-composite is the only material makeup as of yet to achieve this rating, utilizing an ultra-hard ceramic strike face to break apart the bullet, and a UHMWPE or fiberglass backer bonded to the ceramic to absorb the trauma and absorb the fast moving fragments.

SRT

SRT is a special category of body armor that is also not rated by the NIJ, instead it is a manufacturer rating used to describe a plate that is focused on intermediate cartridge threats like 5.56 and 7.62×39. Often times these plates forego any sort of Level III certification due to penetration or excessive back face deformation from 7.62×51. Focusing on intermediate threats allows these plates to be remarkably light and thin, hence why these are called “Special Rifle Threat.” 

NIJ 01.01.07 Standards

The .07 standards were announced and expected to be published a few years back, however we are still awaiting official publication from the NIJ. As discussed, the NIJ currently has five threat levels and the .07 rendition would have two specific levels of pistol armor, HG1 and HG2, and three specific levels of rifle protection RF1, RF2, and RF3. Additionally, the .07 standards is expected to include improved testing on female-specific body armor.

HG1: Would be tested using 9mm FMJ and 357 Magnum soft points, the equivalent of current level II

HG2: Would be tested using 9mm FMJ and 44 Magnum hollow points, similar to the current level IIIA

RF1: Would be tested using 7.62×51 M80 ball (The current test round for Level III), as well as 7.62×39, and 5.56 M193, a very fast round. However the requirements to stop 6 rounds has been decreased to 3 rounds.

RF2: Would be tested using all the same rounds as RF1, with the addition of 5.56 M855. Functionally, this would make RF2 equivalent to the current level III+.

RF3: Would be tested against 30-06 M2 armor piercing, the same as the current Level IV standards.

To learn even more about the NIJ levels, please see our Comprehensive Guide To Body Armor Levels.

Body Armor Plate Materials & Types

Body armor is made of many different materials, all of which have a relevant place in the industry. However, understanding the nuanced differences and navigating opinions on the internet can often be overwhelming. 

AR500 and AR600 Steel Body Armor

AR500 and AR600 body armor are popular types of steel body armor plates. Steel plates are heavier than some other materials, like ceramic or UHMWPE, which can affect mobility and comfort.

The ‘AR’ in AR500/AR600 body armor stands for “Abrasion Resistance,” a universally accepted metric used to measure how hard a material is on the Brinell Hardness Scale. The higher number a material has indicates it is more resistant and harder than lower levels. In the context of steel body armor, that means AR600 is stronger than AR500, and therefore can be made thinner and still offer the same or greater protection. However, as hardness increases so does brittleness, making it important to balance the tradeoff.

Steel armor is by far the most common rifle plate in circulation for the civilian sector and the benefits of steel body armor remain highly relevant due to their exceptional durability and formidable protection against various threats. 

Steel Armor Weight

Steel armor is renowned for its durability and ability to stand up to repeated impacts, however it is also the heaviest body armor on the market due to its material makeup. A typical 10×12” steel plate can weigh between 6.5-10lb depending on the Abrasion Resistance (AR) of the steel used, manufacturing process, and coating. This weight is an important consideration when it comes to the trade offs between steel and other materials.

While the weight may be a drawback for some, keep in mind that steel is more affordable, durable, and has greater longevity in addition to offering protection against a wide range of threats.

Steel Armor Cost

Steel is a very common armor choice due to its price point. A retail steel plate will often run between $100-$200+ depending on factors such as size, thickness, and additional features like anti-spall coatings. However, it is common to find inexpensive non-NIJ Certified steel plates. Non-certified steel plates should be approached with caution. While they may offer some level of protection, their performance under various threats and conditions is not guaranteed. Choosing non-certified plates can be risky, as they may not provide the expected level of protection.

Investing in high-quality, certified steel body armor is a wise decision for those who prioritize their safety. Minor savings on armor costs should not come at the expense of protection, especially when the cost increase is minimal in this case. 

Tacticon Armament steel plates are certified by the NIJ. To maintain certification these plates undergo consistent, rigorous, and specific manufacturing processes to ensure quality and protection. Each batch of Tacticon steel armor is batch tested against penetration and back face deformation. Similarly, each batch is also tested to ensure fragmentation is contained after repeated shots. Always assess whether a type of armor fits your need, research reputable manufacturers, and choose steel armor that you can trust.

Steel Armor Protection Level

Steel plates are rated within the Level III and Level III+ categories.

• Level III Protection: Steel body armor plates rated at Level III are designed to stop 7.62x51mm NATO rounds. These plates can also stop handgun rounds effectively. For individuals looking for affordable protection against rifle fire and handguns level III steel plates are a solid choice.
• Level III+ Protection: Some steel body armor plates are designated as Level III+, indicating they can effectively stop not only 7.62x51mm NATO rounds but also more challenging threats like M855 ammunition. This enhancement gives level III+ steel plates greater all around protection.
• Challenges with M193 5.56 Rounds: While Level III steel plates can handle a wide range of threats, some encounter difficulties stopping high velocity M193 5.56mm ammunition. 
• Higher Brinell Hardness Steel (AR600): To address the challenge posed by M193 5.56 rounds some steel plates are manufactured using higher Brinell Hardness steel, such as AR600. This type of steel offers increased resistance to penetration, making it more effective against high-velocity projectiles. AR600 steel plates are designed to provide protection against a wider range of threats.

Bullet Fragmentation and Spall     

In considering steel it’s important to understand bullet fragmentation and spall. Because of its nature, when steel is impacted by a bullet, the bullet will break apart when it strikes the steel plate. These bullet fragments then fly parallel to the plate’s surface which can result in injury to the wearer’s extremities, neck, and face.

Conversely, spall occurs on the opposite side of the plate when struck by a bullet. Spall are pieces of the plate itself that splinter/flake off from the plate due to the energy transfer. Both bullet fragmentation and spall can harm the wearer, but there are simple solutions.

Fragmentation coating comes standard on all Tacticon steel armor plates is a type of polyurea that is sprayed onto a cleaned metal plate. This polyurea maintains its flexibility and captures the bullet fragments after impact.

In a recent in-house test, the Tacticon AR600 plate was able to take 33 rounds of M855 from an 18in barrel before any fragmentation escaped the plate carrier. This same coating also eliminates the dangers of spall.

Alternatively, a steel plate can be interested into a spall sleeve, kind of like a sock for your plate. However, instead of being made of cotton they are made of either high-strength nylon or Kevlar, and perform a similar function as fragmentation coating, although not as durable as frag coating. Steel is not the only armor that comes with fragmentation risks, ceramic armor will also fragment out the front when struck. 

Warranty Period

Steel body armor will generally come with a 20 year warranty period. There is a common misconception that warranty period means expiration date, this is not the case. In reality, this period denotes how long the plate is guaranteed to be free of defects. Materials used in body armor do break down over time, and with harsh treatment, however the warranty period serves as a manufactures guarantee of function, not a hard-and-fast expiration.

Pros of Steel Body Armor

Steel stands out in several key aspects which make it a popular choice among users. From its cost-effectiveness to remarkable durability, steel plates have unique qualities that set them apart from other body armor materials. 

• Cost-Efficiency: Steel body armor offers an excellent balance between price and performance. When you choose steel plates, you’re opting for the most budget friendly option among rifle rated plates. Affordability allows more individuals access to reliable protection without breaking the bank.
• Exceptional Longevity: One advantage of steel plates is their impressive lifespan. With a standard warranty period of 20 years, steel body armor outlasts all other options on the market. This means your investment will continue to provide reliable protection for decades to come.
• Unmatched Durability: Steel rifle plates are incredibly durable and don’t need special handling or storage conditions. 
• Multiple Hit Resistance: Steel body armor is designed to take hits without shattering. Unlike ceramic plates which fracture upon impact, steel maintains its structural integrity, allowing it to stop successive rounds. This multi-hit capability means a steel plate can take several rounds, even close together, and maintain the same level of protection. 
• Slim Profile: Even with the addition of a fragmentation coating most steel plates maintain a relatively slim profile, measuring approximately 0.65 inches in thickness. This slim design minimizes bulkiness making it easier to shoulder a rifle, conceal armor, and much more.

Cons of Steel Body Armor

While steel body armor has its merits it is not without limitations and drawbacks. 

• Weight: One of the most noticeable downsides of steel body armor is its weight. Compared to ceramic armor steel plates can be notably heavier, often weighing 2-4 pounds more. Keep in mind the extra weight of steel plates can wear you down and make you uncomfortable.
• Fragmentation and Spall Risk: Fragmentation and spall means the user must make sure the plates have some ability to mitigate these dangers. Poorly manufactured steel plates lack proper fragmentation or spall coating and pose a serious threat to the wearer. If stuck without mitigation these plates will produce secondary injury from the rounds. To mitigate the risk buy high quality steel plates with spall coating, or an buy additional spall sleeve to protect yourself.
• Vulnerability to Certain Rounds: While effective against many threats, steel plates have their vulnerabilities. These plates will not stop armor piercing rounds, and many are vulnerable to M193 5.56 rounds. 

Ceramic Composite Body Armor

Ceramic body armor plates are the premiere of modern body armor. When we say ceramic body armor or ceramic armor plates we are referring to either ceramic composite stand alone plates with a backer built in or ceramic in conjunction with ceramic inserts. 

The most common backer material for ceramic plates is UHMWPE which consists of layered sheets of UHMWPE bonded to the ceramic strike face before the plate is sealed in the outer wrapping. 

When a bullet strikes the plate the ceramic shatters the round, as well as the ceramic itself in the immediate area of impact. The backer catches all fragments and continues to slow any remaining pieces of the projectile, all the while dispersing the force of the impact.

In-conjunction-with plates work in the same way, however they have a very thin bonded backer. The plate is slid into a pouch in front of the soft body armor the user is already wearing. The soft armor then acts as a backer for the ceramic. This is seen more in the military and specialized law enforcement units where the user is already wearing soft armor. The major benefit of an in-conjunction-with system is the modularity and ability to scale up or scale down the level of protection.

Ceramic Body Armor Materials

The material makeup for bullet resistant ceramics is fascinating and helps explain the weight and price variations in ceramic body armor. 

Aluminum Oxide

Aluminum Oxide is commonly referred to as Alumina and is the most used ceramic in body armor. It is created by combining aluminum and oxygen through a process called sintering to create a hard and dense compound. Due to the process, it can be made thicker than other ceramics and is the least expensive ceramic used to make body armor. The only downside is it is also the heaviest ceramic material. 

Silicon Carbide

Silicon Carbide is made by combining sand and petroleum under very high heat to bond the silicon and carbon. This mixture is lighter than Alumina but heavier than Boron Carbide. Silicon Carbide can be brittle and less resistant to cracking compared to other ceramic materials. Silicon Carbide offers a balance between weight and strength, it is a more expensive option but not entirely unreasonable.

Boron Carbide

Boron Carbide is the creme de la creme of ceramic body armor. In fact, it is the third hardest material known to man, only behind diamond and cubic boron nitride. Boron Carbide is black crystalline in makeup and has a low density as well as extreme hardness. Of course, it is also extremely expensive, and body armor made from this material is often more than $1,000 per plate. 

Aluminum Oxynitride

Aluminum Oxynitride, referred to as ALON, is not used in body armor as ALON is generally heavier than other materials used in protective gear. Rather it is used in vehicle armor, bulletproof glass, and bulletproof goggles. It begins its life as a powder, which is then sintered to become a transparent polycrystalline ceramic, later sanded and polished to be as transparent as glass. Nonetheless, its unique combination of optical clarity and ballistic resistance makes it a valuable choice for specialized protective applications.

Ceramic Body Armor Weight

Ceramic plates vary in weight, typically ranging from 4 to 10 pounds per plate, depending on the specific ceramics used and the dimensions of the finished plate. When considering the weight of ceramic body armor there’s often a tradeoff between weight and price, meaning that lighter plates tend to be more expensive. Remember the rule of thumb I mentioned earlier?

However, it’s important to note that this trade off reaches a point of diminishing returns. For Level IV plates, this typically occurs at around the 6-pound mark, while for Level III and 3+ plates, it’s generally around the 5 pound mark.

Managing weight is an overlooked factor in selecting body armor. While lighter plates offer greater mobility and comfort, they often come at a higher cost. It is important to find a balance between the two. 

Ceramic Body Armor Cost

The cost of ceramic plates varies depending on several factors, including the type of ceramic used and the weight of the plate. Entry level Alumina plates typically weigh between 8-10 pounds and can be found starting at around $120. As you move into the 5.5-7 pound range, the price range widens considerably with plates ranging from $250 to $800 or even more depending on the manufacturer and specific features.

The price begins to increase exponentially for plates weighing less than 5.5 pounds. While lighter plates have obvious advantages, they come at a premium cost. When choosing ceramic body armor consider your budget and how much a pound or two means to you. 

Ceramic Body Armor Threat Levels

Ceramic plates are incredibly versatile when it comes to threat levels. They can be manufactured to meet a range of ratings, including SRT, Level III+, and NIJ Level IV. What sets them apart is their ability to achieve the highly sought-after NIJ Level IV rating. This means that ceramic plates can be made to offer protection against armor penetrating rounds that other materials simply cannot match. When it comes to stopping bullets designed to penetrate armor, ceramic body armor is the only choice.

Warranty Period

The warranty period for ceramic is similar to the warranty for Ultra High Molecular Weight Polyethylene, and it is not actually for the armor. Rather, the warranty is for the raw materials from the original manufacturer. As these materials age they break down, which is accelerated by heat and abuse. The bond between the ceramic and UHMWPE can also begin to separate with age. Most raw materials are warranted for 5 years, however the material and armor is often used well beyond this period. Basically, the warranty period is a general guide rather than a hard and fast expiration. Of course, for liability reasons, the armor is only guaranteed for as long as the materials are from the manufacturer of the raw material. 

Pros of Ceramic Body Armor

• High NIJ Rating: Ceramic composite body armor can achieve the highest NIJ rating of Level IV. This offers protection against armor penetrating rounds, providing a high level of security in dangerous situations.
• Lightweight: Ceramic armor is notably lighter than steel. This reduced weight contributes to increased mobility for the wearer, making it easier to move and react. Lighter armor can be especially important for those who need to maintain agility while staying protected.
• Reduced Trauma: Ceramic plates are designed to absorb and disperse energy upon impact, which helps reduce the blunt force trauma experienced by the wearer. This results in a decreased risk of injury from the backing material.
• Durability: Ceramic armor is relatively durable overall, especially plates that feature padding over the strike face. 
• Broad Range of Applications: Ceramic body armor is suitable for a wide range of applications and threats, leading to its use in the military and law enforcement. 

Cons of Ceramic Body Armor

• Successive Round Protection: Ceramic body armor is not as protective against successive rounds as steel. After absorbing the impact of one round, the ceramic in the immediate area shatters, compromising the ballistic protection in that area. This is why the NIJ requires test shots to be placed 2” apart during testing.
• Higher Cost: Ceramic armor is generally more expensive than steel armor. The advanced materials and manufacturing processes used in ceramic plates contribute to their higher cost. This expense can be a deterrent for individuals with budget constraints.
• Fragility: Fragility can be a concern with ceramic plates, especially if they are dropped or poorly maintained. Ceramic materials are more brittle than steel, and impacts or mishandling can lead to cracks or fractures in the plates.
• Limited Warranty: Most ceramic composites come with warranties ranging from 5 to 10 years. While this duration provides a reasonable period of protection, it is less than steel armor. The armor may still be viable, but should not be relied on in the same manner. 
• Risk of Fragmentation: Ceramic plates have the risk of fragmentation when struck. Since these fragments are moving relatively slowly they are often contained within the plate carrier. 
• Specialized Care: Ceramic body armor requires careful handling and maintenance to ensure its longevity and performance. Users must follow manufacturer guidelines for care, storage, and inspection to avoid potential issues.

UHMWPE Body Armor

ULMWPE is Ultra High Molecular Weight Polyethylene, a compound of extremely long fibrous chains. As mentioned earlier it was accidentally discovered in the 1890s during an attempt to make a gasoline additive. Forty years later, two scientists in England were attempting to do the same thing and came up with a compound that was waxy, white, and had terrific insulating properties. 

During the Second World War Allied countries began using this to replace latex in radar cables, and it remained a closely guarded secret during the war. With continued experimentation, polyethylene was used to create many different plastics, even in joint replacements and other medical applications. In the 1970s experimentation began for possible uses in body armor. 

Today, UHMWPE is used to form ceramic + UHMWPE composite plates, but also soft armor and pure UHMWPE rifle armor. Soft UHMWPE armor is created by layering sheets to a desired thickness, and then sealing the panel.

This leads to a very light, very flexible soft armor panel. When used to create hard armor plates, either pistol or rifle rated, UHMWPE is pressed to a certain thickness based on the intended threat rating, and then pressure treated to create a rigid, but incredibly lightweight armor plate. Pure UHMWPE Level III rifle plates can stop virtually any round that does not contain a steel or tungsten penetrator. They fail to stop these because they lack a strike face to break apart the round in the same way ceramic plates do. 

UHMWPE Weight

UHMWPE body armor excels in terms of weight in the form of soft armor panels for concealable vests or hard armor plates for rifle protection. Soft armor panels for a bulletproof vest will generally weigh 2-3.5 pounds per panel. For rifle protection, plates made of UHMWPE can range from 2.5-4 pounds depending on the rounds they are designed to stop. 

The exceptional weight-to-protection ratio of UHMWPE body armor makes it a preferred choice for those who aren’t worried about armor piercing or steel core rounds.

UHMWPE Body Armor Cost

The cost of UHMWPE body armor reflects its advanced materials and performance. While it’s true that UHMWPE is relatively more expensive than other materials used in body armor, it’s important to consider the value it offers in terms of weight reduction.

A pure UHMWPE Level III hard armor plate typically falls in the price range of $300 to $500 or more, depending on factors such as size, thickness, and specific manufacturer features. While this may seem like a significant investment, remember UHMWPE plates are not only incredibly lightweight but also offer exceptional ballistic resistance. 

When it comes to soft armor panels for bulletproof vests, UHMWPE continues to shine. These soft panels can be found in the price range of $200 to $250 or more, depending on the vest’s specific design and the level of protection it offers. UHMWPE soft armor is incredibly popular despite being more expensive than Kevlar. 

While UHMWPE body armor may have a relatively higher upfront cost, it brings a host of advantages that justify the expense. The lightweight nature of UHMWPE materials, coupled with their remarkable ballistic performance, makes them a valuable choice.

UHMWPE Body Armor Threat Levels

Pure UHMWPE has limitations because it lacks a hard strike face. As a result, it cannot achieve a rating higher than NIJ level III, making it ineffective against armor piercing rounds or steel penetrator rounds like M855. However, UHMWPE excels in soft armor applications where it’s used to manufacture level IIIA rated armor.

Additionally, UHMWPE is employed in the creation of level IIIA hard pistol plates for use in a plate carrier. 

Warranty Period

Most UHMWPE body armor comes with a warranty period similar to ceramic plates of around 5 years. Exposure to excessive heat or corrosive substances, oils, etc. accelerate wear and tear on the material, reducing the plates lifespan. Additionally, how the armor is handled particularly when it comes to folding or storing impacts the life span of soft armor. Therefore, it’s advisable to follow manufacturer guidelines for proper care and maintenance to so your UHMWPE body armor remains in good condition.

Pros of UHMWPE Body Armor

• Lightweight: UHMWPE body armor is incredibly lightweight, allowing the user to add more gear, move more quickly, and be more comfortable overall.
• Durability: UHMWPE body armor is very durable, it will not crack like ceramic can if abused. The only real threats to UHMWPE are chemicals and heat. And bullets….
• Buoyancy: UHMWPE’s natural buoyancy makes it ideal for waterborne operations. This property helps individuals stay afloat while wearing body armor, rather than it acting as an anchor. 
• Versatile Rifle Threat Protection: UHMWPE body armor can stop a wide range of threats, assuming they are neither armor piercing or steel core. 
• Lighter Than Kevlar: UHMWPE’s soft armor is even lighter than traditional Kevlar, which is one of the many reasons law enforcement has gravitated towards it. 

Cons of UHMWPE Body Armor

• Susceptible to Certain Rifle Rounds: UHMWPE body armor is effective against a wide range of threats, but vulnerable to steel core ammunition such as M855 and 7.62x39mm MSC, as well as armor piercing rounds. Users must consider the types of ammunition they may encounter in their specific environments.
• Cost Considerations: UHMWPE body armor can be relatively costly compared to some alternatives. 
• Increased Thickness: Level III UHMWPE plates are thicker than other materials, often exceeding 1-1.5 inch in thickness. This added thickness may affect user mobility, and limit plate carrier choices and sizes.
• Heat and UV Sensitivity: UHMWPE body armor can be sensitive to heat and UV exposure. Prolonged exposure to high temperatures or direct sunlight, such as leaving it in a car, may impact its ballistic performance over time. Users should store and maintain their UHMWPE armor appropriately to ensure its effectiveness.

Kevlar and Aramid/Para-Aramid Body Armor

Aramid fibers and their derivatives are the fundamental components of modern body armor, and origin of the bulletproof vests. Aramid fibers are a class of synthetic fibers known for their exceptional strength and heat-resistant properties. The term “aramid” is derived from “aromatic polyamide,” which describes the chemical structure of these fibers. Aramid fibers are created through a process that involves spinning long-chain polymers into fibers. The term “para” in para-aramid refers to the specific orientation of the aromatic rings in the polymer chains.

In para-aramids, the rings are aligned parallel to each other, which contributes to their high tensile strength. Both Aramids and Para-Aramids have remarkable tensile strength, making them extremely resistant to stretching or breaking when subjected to force.

Aramid fibers, including Kevlar are synthetic, heat-resistant, and exceptionally strong materials. These fibers have become a popular choice for soft body armor due to their inherent durability and impressive tensile strength. Para-aramid fibers, like Kevlar, are part of the broader aramid family, distinguished by their exceptional resistance to impact, making them ideal for protecting against ballistic threats. To learn more, check out our Aramid vs Kevlar article.

Trailblazers of Kevlar

Kevlar is synonymous with two people in particular whose ingenuity led to modern body armor. First Stephanie Kwolek found the compound during an experiment at DuPont. She created a crystalline liquid that becomes incredibly strong once woven into fibers. 

Richard Davis is the inventor of the bulletproof vest, and his larger-than-life story is actually true. After leaving the U.S. Marine Corps he became the owner and delivery driver of a pizza joint in Detroit. After being robbed several times at gunpoint he set out to create body armor in the event someone actually pulled the trigger.

During his experimentation, he discovered several layers of Kevlar actually made an effective vest against most handgun rounds. It was also flexible, which armor hadn’t been up to this point. He founded Second Chance Body Armor in 1970, and the stories are true. He took the show around the country and would shoot himself in the chest to demonstrate the effectiveness of Kevlar vests. By the 1980’s Second Chance Body Armor was one of the largest bulletproof vest providers to law enforcement. 

Kevlar is rated to have a tensile strength of about 5 times that of steel which allows the armor to distribute the force of an impact across a large surface area. This is highly effective because of the unilateral weave found in the material sheets. 

Kevlar Body Armor Weight

Kevlar body armor is slightly heavier than newer UHMWPE, weighing 2-4 pounds for the soft armor panels used in bulletproof vests. Overall, this was a complete revolution in body armor when it first came out, and for years to come.

Kevlar Body Armor Cost

The cost of Kevlar body armor can vary widely based on several factors. These factors include the manufacturer’s reputation, the production methods employed, protection level (such as Level II or Level IIIA), certifications like NIJ approval, market demand fluctuations, additional accessories, and the extent of warranty and support provided. Depending on these factors, Kevlar body armor can range in price from approximately $250 to $500 or more for a bulletproof vest.

Warranty Period

The warranty period for Kevlar body armor typically spans five years, aligning with the warranty provided by the materials manufacturer and the expected lifespan of Kevlar or aramid fibers. Kevlar body armor is often worn underneath clothing and used regularly, making it more susceptible to exposure to sweat and body oils. As a result, adhering to this recommended warranty period is more important to ensure the armor’s continued reliability and performance.

This recommendation holds true not only for Kevlar but also for soft body armor in general, given the similar usage and environmental conditions it encounters during daily wear. Regularly following the warranty guidelines can help maintain the protective qualities of Kevlar body armor, ensuring it remains effective and reliable throughout its service life.

Kevlar Body Armor Threat Levels

Aramid materials like Kevlar are primarily utilized in the production of soft body armor due to their flexible and lightweight properties. The most prevalent level of soft body armor available today is Level IIIA, offering protection against a variety of handgun rounds.

Kevlar has been used to manufacture Level IIA and Level II soft body armor variants as well. Level IIA armor provides a lower level of protection against handgun threats, making it suitable for situations where reduced bulk and greater mobility are desired. Level II armor offers greater protection against a broader range of handgun rounds. This flexibility in threat level options makes Kevlar a versatile choice for soft body armor.

Pros of Kevlar and Aramid Body Armor

• Proven Track Record: Kevlar and aramid fibers have a well established history of use in soft body armor, making them a trusted choice. These fibers have consistently demonstrated their effectiveness in providing protection.
• Affordability: Body armor constructed from aramid fibers is relatively affordable compared to some other materials, ensuring that individuals with varying budgets can access quality protection.
• Lightweight: Aramid fibers are known for their lightweight properties, making body armor comfortable to wear for extended periods. This lightweight feature enhances maneuverability and reduces fatigue during use.
• High Temperature Resistance: Aramid fibers exhibit high-temperature resistance, which is advantageous in situations where heat or fire may be a concern, ensuring that the armor maintains its integrity.
• Effective Protection: Level IIIA body armor, made from aramid fibers, provides protection against common handgun threats, covering the vast majority of gun-related crimes. This level of protection ensures the wearer is shielded from various firearm projectiles.
• Shotgun Round Stopping: In addition to handgun threats, aramid-based body armor can stop most shotgun rounds, adding versatility to its protective capabilities.

Cons of Kevlar and Aramid Body Armor

• Comparatively Lower Tensile Strength: While aramid fibers offer a lower tensile strength than materials like UHMWPE, which is approximately 15 times stronger than steel.
• Heavier Than UHMWPE: Aramid body armor tends to be heavier than modern UHMWPE armor. This added weight can impact wearer comfort and agility, particularly during prolonged use or in situations that require increased mobility.
• Limited Protection: One of the drawbacks of aramid-based body armor is its limitation in stopping rifle threats or armor piercing rounds. These materials are used for soft body armor that is primarily designed to protect against handgun and shotgun threats.
• Moisture Sensitivity: Aramid fibers can absorb moisture over time, which can affect their ballistic performance. Prolonged exposure to humidity or moisture can lead to a decrease in the material’s protective capabilities.
• Degradation Over Time: Like many materials, aramid fibers can degrade with prolonged use and exposure to environmental factors. This degradation can impact the effectiveness of the armor over time, making it essential to follow manufacturer recommendations for replacement.

Body Armor Cut Types

When it comes to body armor, one size or shape doesn’t fit all. The diversity in body armor cuts and styles serves to optimize protection and accommodate user preferences. Body armor cuts refer to the different patterns or designs used in manufacturing of body armor, such as bulletproof vests. These cuts determine the coverage and fit of the armor, and they are tailored to meet various needs and preferences of users. Understanding the various cuts is important in finding the best personal balance between maneuverability and coverage. Let’s now explore the nuances and advantages of each.

Soft Armor Cuts

What sets soft armor apart is its adaptability, not only in terms of materials but also in dimensions and designs. Manufacturers craft soft armor with various cuts due to how easy the materials are to work with. These cuts dictate the coverage and fit of the armor, allowing individuals to choose the style that best aligns with their specific requirements. Here are some common soft armor cut types:

Panel Design: This is perhaps the most popular design for soft body armor used in bulletproof vests. Panels are crafted to provide extensive front, back, and side protection. The additional material wrapping around the sides under the arms ensures comprehensive coverage.

Shooters Cut Panel: While this design follows the traditional 10×12″ rifle plate pattern with an angled cut at the top for better arm movement, it sacrifices some coverage for increased concealability. The slim profile makes it an excellent choice for those prioritizing discretion.

Hard Armor Cuts

Hard armor is made of rigid rifle plates designed to stop rounds soft armor can’t. The cut of the plate impacts the users shoulder mobility, weight of the plates, and coverage.

SAPI vs. Shooter Cut Body Armor: SAPI (Small Arms Protective Insert) plates were initially designed for the U.S. Military. SAPI plates come in various sizes, setting a standard for military use and civilian armor.

Although similar in design, shooter cut plates have some distinctions shaving off material from the plate’s lower corners to enhance mobility and save weight. The standard shooter’s cut plate measures 10×12″, while SAPI plates have specific sizes, catering to different body types.

Swimmer Cut: Swimmer cut plates prioritize mobility and weight reduction. They feature a more gradual angle of cut for the upper corners, making the plate lighter and more comfortable for dynamic movement. Swimmer cut plates are ideal for those seeking enhanced agility and are willing to sacrifice coverage.

Hybrid Cut: Exclusive to steel armor, hybrid cut plates combine the shooter’s cut on the non-dominant side and the swimmer’s cut on the dominant side where the rifle stock is shouldered. This clever design, unique to steel armor, optimizes maneuverability without sacrificing protection.

Backpack Armor: Rectangular in shape and typically measuring 10×12″ or 12×15″, backpack armor is designed to maximize coverage while fitting seamlessly into various backpacks, ensuring protection without compromising the bag’s structure.

Body Armor Manufacturing

In our ongoing exploration of body armor, we turn our attention to manufacturing. In this next section we will shed light on the manufacturing processes behind different types of body armor, from the robustness of steel to the cutting-edge technology of ceramics, the versatility of UHMWPE, and the trusted reliability of Kevlar. We’ll also share the crucial aspects of mitigating fragmentation and spalling risks to ensure comprehensive protection.

Steel Armor Manufacturing

Diving into steel armor production takes us on a journey through the hands-on methods and specialized steps that craft this formidable protective gear. Let’s get started.

1. Material Selection: The process begins with the selection of high-quality steel. This steel is treated to achieve the desired hardness and durability required for body armor use. The specific type of steel and its unique properties play a crucial role in the final product’s effectiveness.

2. Cutting and Shaping: Once the steel is acquired, it’s cut into the desired shape and dimensions. Commonly, steel armor plates are designed to fit standard sizes such as 10×12 inches. Precision cutting ensures that the final product meets the required standards for protection and comfort, without leaving rough edges.

3. Treatment: The cut steel pieces then undergo a treatment process to remove all dirt, oils, debris from the surface of the plate.

4. Coating Application: After treatment, a protective coating is applied to the steel plates. This coating serves multiple purposes, including corrosion resistance and minimizing the risk of spall and fragmentation upon impact.

5. Quality Control: Quality control is a critical aspect of steel armor manufacturing. Each plate is carefully inspected to ensure it meets the specified standards. This involves thorough examination for defects, proper sizing, and adherence to weight requirements.

6. Testing: Randomly selected plates from the production batch undergo rigorous testing to evaluate their ballistic performance. This testing helps verify that the armor can effectively stop projectiles and meet the required safety standards.

Manufacturing steel body armor is a combination of precision engineering and metallurgical expertise. The process is designed to produce armor that offers superior protection while being durable and reliable in various situations.

Ceramic Armor Manufacturing

Creating ceramic body armor involves a specialized manufacturing process that harnesses the unique properties of ceramics to provide life-saving protection. These plates employ advanced ceramics like alumina or silicon carbide as their core materials, chosen for their exceptional hardness and ability to withstand high veocity impacts.

1. Material Selection: The journey to crafting ceramic body armor plates commences with the careful selection of materials. Alumina is a popular choice for its remarkable hardness and affordability. Silicon carbide is another that offers exceptional toughness and lighter weight. These ceramics provide the rigid structure and ability to shatter incoming rounds.

2. Formation: Once the appropriate ceramic material is chosen, it’s meticulously processed into the desired plate shape. The shaping process involves precise cutting, grinding, and pressing to achieve the required dimensions and curvature. This initial phase sets the foundation for the plate’s ability to absorb and disperse the energy of incoming projectiles.

3. Sintering: The formed ceramic then undergo a foundational step called sintering. This process involves subjecting the plates to extremely high temperatures, often exceeding 2,000 degrees Celsius. During sintering, the ceramic particles bond together, creating a dense, solid structure. This transformation enhances the ceramic’s hardness and strength, making it capable of withstanding the intense forces generated by ballistic impacts.

4. Finishing: After sintering the plates receive meticulous finishing touches. This includes grinding and polishing to achieve the desired thickness, surface smoothness, and curvature. The level of precision and attention to detail in this phase is vital, as it directly impacts the plate’s ballistic performance.

5. Additional Components: Composite backings made from materials like UHMWPE (Ultra-High Molecular Weight Polyethylene) or aramid fibers are bonded to the ceramic to provide support, trauma reduction, and enhance the plate’s overall performance.

The creation of ceramic body armor plates involves a meticulous process that begins with material selection, progresses through shaping and sintering, and culminates in precise finishing. Additional components like composite backings and coatings are integrated to enhance the plate’s ballistic capabilities. The result is a formidable piece of armor designed to protect those who wear it from a variety of ballistic threats.

UHMWPE Manufacturing

UHMWPE (Ultra-High Molecular Weight Polyethylene) is a modern marvel of body armor materials when you consider its material structure, light weight, and ability to stop bullets.

1. Material Extrusion: The journey begins with the production of UHMWPE sheets. This material is created through a complex extrusion process. It involves melting the UHMWPE resin and then pushing it through a specialized die to form a continuous sheet. The result is a sheet of UHMWPE that possesses incredible molecular weight and density, making it incredibly strong.

2. Layering and Lamination: Once the UHMWPE sheets are produced, they undergo a layering and lamination process. Multiple layers of UHMWPE are stacked together, with each layer oriented in a different direction. This cross-ply configuration enhances the material’s ability to disperse the energy of incoming projectiles, a crucial feature for effective ballistic protection.

3. Thermoplastic Pressing (Hard armor only): The layered UHMWPE sheets are subjected to extreme heat and pressure, a process known as thermoplastic pressing. This step further fuses the layers together, creating a solid and durable composite material. The pressing process ensures that the UHMWPE retains its exceptional strength while gaining the necessary rigidity for ballistic applications.

4. Cutting and Shaping: With the composite material prepared, it is then cut and shaped into the desired form. This involves precision cutting to create panels of various sizes and shapes, depending on the specific body armor design. Additionally, the panels may be curved or contoured to ensure a comfortable fit for the wearer.

5. Optional Additions: Manufacturers may choose to enhance UHMWPE body armor with optional components. These can include specialized coatings for improved resistance against abrasion and environmental factors, as well as additional backings or layers for enhanced performance.

The production of UHMWPE body armor involves a series of intricate steps, from material extrusion and layering to thermoplastic pressing and final shaping. The result is an incredibly lightweight option for modern body armor.

Kevlar Manufacturing

Kevlar is a staple in the world of body armor for its long use and pioneering the bulletproof vest.  

1. Polymerization: The journey of Kevlar body armor starts with a process called polymerization. In this step raw materials known as monomers derived from petroleum, are transformed into long chains of polymeric molecules. These chains form the basis of Kevlar’s exceptional strength. The resulting polymeric material is then spun into fibers.

2. Spinning Process: Once the polymeric material is ready, it undergoes a spinning process. During spinning, the polymer chains are stretched and aligned, further enhancing their strength. This process is akin to stretching a rubber band to maximize its elasticity. The result is a bundle of incredibly strong and stiff Kevlar fibers.

3. Weaving and Layering: After spinning, Kevlar fibers are woven into sheets or fabrics. These sheets can be layered to increase their protective capabilities. The weaving and layering process is a critical step, as it determines the structure and density of the Kevlar material, which ultimately affects its ability to stop bullets and other ballistic threats.

4. Impregnation and Coating: To optimize its ballistic performance, Kevlar is often impregnated with a specialized resin. This resin further reinforces the material, making it more resistant to penetration. Additionally, some Kevlar body armor may receive a protective coating to enhance its durability and resistance to environmental factors.

5. Cutting and Shaping: Once the Kevlar material is prepared, it is cut and shaped into panels of various sizes and configurations. Precision cutting ensures that the panels fit seamlessly into body armor designs. These panels may be curved or contoured to offer both protection and comfort to the wearer.

Fragmentation and Spalling

Protection goes beyond merely stopping projectiles. Understanding the phenomenon of fragmentation and spalling is important for appreciating the full spectrum of ballistic defense and understanding how it relates to the safety of individuals wearing body armor.

What is Fragmentation?

Fragmentation refers to the process of a bullet or projectile breaking apart upon impact with a target. This fragmentation results in the formation of high velocity fragments or splinters that disperse in various directions from the point of impact. These fragments can travel at significant speeds and pose a severe threat to anyone in their path.

Fragmentation is a concern because it can lead to secondary injuries to the wearer of body armor. While the armor effectively stop the primary projectile, the high energy fragments created upon impact can still cause injury to the wearer’s extremities.

Implications for Body Armor

Body armor isn’t just about stopping bullets; it must also minimize the risk of secondary injuries caused by fragments. To achieve this, various strategies and materials are employed in armor design.

Spall and Spall Coating

In addition to fragmentation, another critical consideration is spalling. Spalling occurs when a projectile strikes the surface of hard armor, such as steel or ceramic plates. The impact can cause the outer layer of the armor to fracture or chip. These spall fragments can injure the wearer.

To mitigate spalling, manufacturers often apply a spall coating to the front face of hard armor plates. This coating serves as a protective layer that traps and contains any fragments that may result from an impact. By doing so, it minimizes the risk of spalling related injuries to the wearer.

Exploring the Craftsmanship of Body Armor

Understanding how these life saving products are manufactured is not only fascinating fundamental to appreciating the technology that keeps us safe. To discover more about the intricate world of body armor manufacturing, we invite you to explore our article on “How is Body Armor Made“.

Yet, the journey doesn’t end here. The importance of body armor goes beyond its mere creation; it’s about how these body armor products perform under fire. To gain a comprehensive understanding of the effects of ballistics on body armor, and the phenomenon known as fragmentation, continue your exploration with our in-depth What is Fragmentation article. Together, these insights offer a profound glimpse into the science, technology, and craftsmanship behind the armor that safeguards those who wear it.

Body Armor Maintenance

Ensuring the reliability of your body armor should be a priority for those who trust their life to it. In this next section, we will explore various aspects of body armor maintenance, including best practices for storage, valuable tips and tricks for upkeep, and general care guidelines. Your armor is your lifeline, and it deserves the utmost care and attention.

Body Armor Storage

Body armor storage is an essential part of maintaining gear that is frequently overlooked. Without proper armor storage, plates can become weakened due to material stress, the environment, or improper care. Maintaining the protective capabilities of armor is important to ensure its life saving abilities. 

Soft Armor Storage

Preserving the integrity of your soft body armor is essential for its long-term effectiveness. From keeping it flat to shield it from UV light, and ensuring it’s thoroughly dry, we’ll explore the best practices that will help your armor maintain its protective capabilities over time. Your safety depends on the condition of your gear, and proper storage is a key element in ensuring its reliability.

1. Keep it flat: Soft armor should be stored flat or in the vest/carrier it is worn in. Folding panels during storage causes premature wear along the folds resulting in weakened fibers. Moisture can also lead to the weakening of fibers, lowering the effectiveness over time. 
2. Avoid UV light: UV light is harmful to soft armor fibers. Exposure to direct sunlight for long periods of time causes fiber degradation. Maintain the armor’s integrity by avoiding UV light. 
3. Drying time: In the event that armor becomes wet, air dries the armor completely and fully before storage or reinsertion. Damp armor will mold and accelerate fiber breakdown. 

Following these basic guidelines will ensure the armor will prevent early wear and decreased effectiveness. 

Hard Armor Storage

Hard armor follows many of the same general rules as soft armor. However, since hard armor plates are rigid they are inherently more fragile. The dangers of cracking and breaking with a hard impact must be taken into account during storage. 

1. Careful hanging armor: Hanging armor in a plate carrier will stretch the shoulders of the carrier itself. Further unless a heavy-duty, body armor specific hanger is used then it may break, resulting in the plates falling and potentially cracking. 
2. Keep it flat: Hard armor can be stored flat, or still in the plate carrier propped against a wall ready to go.
3. Avoid UV light: Hard armor should still be kept out of direct sunlight for prolonged periods as this can cause delamination in UHMWPE plates and damage the bond between UHMWPE and ceramic for composite plates. 
4. Avoid dropping plates: While they are rigid and hard by nature, the harder something is the more brittle it is as well. 

Cleaning & Care Tips

Throughout its use body armor will get dirty, and it should be cleaned but there are specific steps to follow. 

1. Never machine wash: Never wash armor in a laundry machine. It has happened. The same goes for plate carriers, they use Velcro and hot water can destroy Velcro. The best way to wash carriers is to spot clean with mild soap, use room temperature water, and air dry. 
2. Use mild wash with water: You can use mild soap and cool water to wash panels and plates if need be, allow to completely air dry. 
3. Never use harsh chemicals: Don’t use harsh chemicals that can interfere with materials or cause degradation or corrosion. 
4. Inspect regularly: Body armor should be inspected often for tears, cracks, or other signs of damage, and replaced immediately if shot. 
5. Use caution: Don’t drop, mistreat, or otherwise abuse body armor.
6. Follow manufacturer instructions: Above all else, always follow your specific manufacturer instructions. 

When it comes to cleaning less is more. In general plate carriers are made to be dirty and that’s alright, they shouldn’t need to be washed. Mild cleaning methods prevent damage to ballistic materials that could be incurred in more intrusive ways. Knowing how to clean body armor is just as important as knowing how to wear it. 

Body Armor Warranty and Expiration 

It is important to understand the difference between a warranty period and actual expiration. The warranty period on body armor is not actually from the manufacturer of the armor, rather it is from the manufacturer of the raw materials. The original material manufacturer is warrantying the raw materials to do what they are expected to do for a certain period of time. 

Generally, soft armor comes with a warranty period of 5 years. This is also typical of ceramic composite and UHMWPE rifle plates. Steel body armor is the outlier, coming with a warranty of 20 years. 

You may have come across videos on YouTube of body armor stopping the rounds it is rated for well after the warranty period has expired. There is not a hard and fast expiration with these materials like there is with poultry at the grocery store. This is why there are many ESAPI plates at surplus stores, at high prices still. 

Materials do break down over time, fibers degrade, and bonding separates. This happens quicker with abuse and maltreatment, but generally, it takes a long time for body armor to be no longer viable. 

General principles to live by: Take care of your body armor and it will take care of you. Treat your gear as if your life depended on it functioning as designed.

Don’t abuse gear designed to save your life. Don’t drop plates, don’t throw them. Don’t leave your gear out, and avoid the old saying “Run hard and put away wet”. Remember, always consult your specific manufacturer regarding warranty, usage, care, maintenance, questions, and concerns. 

How to Choose The Right Body Armor

Clearly, there are a lot of options out there for body armor, all of which have drawbacks and advantages. It can be quite overwhelming to choose what body armor will work for you, so let’s look at this critically.

Level of Protection

Let’s start with the level of protection that is necessary. Will you need rifle protection because you are likely to face rifle threats? Or will pistol protection suffice? If pistol threats are all you expect to face then we can disregard hard armor (and vice versa). 

3 Steps To Determine Your Protection Needs

1. Threat prevalence: What threats are there and how prevalent are they? If you only expect pistol threats then soft armor may be ideal. However, if rifle threats are prevalent enough to be a concern then hard armor will most likely be the best course of action. 
2. Armor level: What rifle plate will be the most beneficial? Using the same metric, are armor piercing rounds prevalent and a concern? If so level IV will be required. If not then SRT, level III, level III+ plates should do the job. In a rural setting where hunting rifles and other high caliber rifles are present level III plates are the minimum level of protection recommended. 
3. Weight/Mobility trade-off: How much weight do you realistically want to carry? The heavier the armor the more quickly exhaustion sets in under stressful conditions. If intermediate cartridges like 5.56 are common, and larger calibers are uncommon such as in an urban setting then SRT plates may be an ideal balance. 

Size, Fit & Color

Once the threat level is identified it is time to look at the carrier that will be used, how should body armor fit, and the best color options for the area. 

Finding The Right Size

1. Measure Yourself: Start by measuring your own size accurately. This includes your height and weight, which will help you choose the right armor and carriers.
2. Consider Standard Sizes: Soft armor typically comes in standard sizes like small, medium, and large. These sizes can help you narrow down your options.
3. Hard Armor Plate Sizes: For hard armor plates most people who are between 5’3″ and 6’3″ tend to use 10×12-inch plates. If you’re taller than 6’3″ it’s recommended to consider 11×14-inch plates.
4. Choose the Cut: If you’re looking at hard armor, decide whether you prefer a shooter’s cut or a swimmer’s cut. A swimmer’s cut offers a better range of motion and can make it easier to shoulder a rifle while wearing the armor, at the expense of coverage.
5. Plate Carrier Compatibility: Keep in mind that certain plate carriers are designed specifically for swimmers cut plates. However, swimmers cut plates can usually fit in standard carriers without any issues.

Finding The Right Fit

The fitment of the armor, soft or hard should be roughly 1 or so inches below the collarbone at the top of the armor. For hard armor plates, it will generally be about 3 inches above the navel, soft armor will generally extend farther down the torso. 

Shoulder straps should be adjusted so that the armor fits evenly on both sides, and the front and rear plates ride the same height. The cummerbund should be snug so that the armor will not move when you begin running, crouching, or doing any dynamic movement.

However, the cummerbund should not be tight to the point that it begins to restrict breathing if you begin breathing heavily. A little trick, after the plates are inserted and the carrier is snug, jump a few times to ensure the plate carrier remains in place.

Finding The Right Color

The color of your carrier isn’t just about style; it’s about blending in. If you’re opting for concealed soft armor, you can skim through this section. But if you’re going with an overt vest or plate carrier, it’s time to dive into the world of colors.

1. Know Your Environment: Think about where you’ll be wearing your gear. Will it be the arid desert? If so, lean towards earthy tones like FDE or coyote brown. Surrounded by foliage? Go for OD or ranger green. Navigating urban landscapes? Stick with neutral shades like greys and black. Remember, the best camouflage is one that matches your most likely surroundings.
2. Match or Mismatch: Consider how important blending in is to you. Even the best camo carrier won’t help if you’re pairing it with bright blue jeans. Camouflage patterns work by breaking up outlines, making it harder to spot you in the wild. So, unless you’re rocking camo from head to toe, think about how your outfit complements your carrier’s colors.

There’s no one-size-fits-all to camouflage, but by assessing your environment you can get a solid idea of what works for you.

What is Your Mission and Intended Use?

Now, let’s talk about the heart of the matter: what kind of armor suits what you will be using it for?

Option 1: Conceal and Conquer

If you’re all about staying incognito, concealable armor is your go to choice. It’s like a secret superhero suit, offering protection without turning heads. And if you want to take it up a notch, backpack armor is your ace in the hole—armor on the down-low, no one will suspect a thing.

Option 2: Prepared for Anything

Are you the “just in case” or “SHTF” kind of prepper? Steel armor might be your trusty sidekick. It’s like the Iron Man suit of armor, built for the long haul. If your gear’s more for show than action, save some bucks with steel or other hefty materials.

Option 3: Agile and Ready

Now, if you’re all about training hard or on-duty action, ceramics or UHMWPE plates are your workout buddies. They’re the lightweight champs, letting you move swiftly and stay nimble. Whether it’s drills or the daily grind, they’ve got your back.

Your mission and intent will shape your armor choice. Whether it’s blending in discreetly, gearing up for the unknown, or staying agile on the move, your armor is your trusted companion. So, find the one that suits your mission, and embark on your mission with confidence. 

Weight is More Than a Number

When it comes to body armor, weight isn’t just a number; it’s a game changer. Think about your entire loadout and your physical fitness level. Those hefty plates might seem like a great way to save a buck, but if you’re not in peak shape and have a full combat load of magazines, you’re in for a grueling experience.

Picture this: you might need to move fast, cover long distances, or hike with your gear. Remember, as the saying goes, “ounces equal pounds, and pounds equal pain.”

Are you planning to customize your carrier for extended use? A minimalist plate carrier could be the answer, but keep in mind they might not distribute weight as effectively as a fully designed vest.

If you’re aiming for a low-profile, sleek look, minimalist carriers shine. However, they offer less overall support. So, before you decide on something as simple as the plate armor weight, consider your mission, your gear, and your comfort because the right body armor can make all the difference.

Body Armor Accessories

Most body armor carriers are designed to be modular, meaning they go beyond just holding body armor and can have accessories attached and detached to fit the needs of the moment. MOLLE/PALS serves as the current universal mounting solution, and many MOLLE pouches are on the market for a variety of specific uses.

There are also other accessories such as packs and belts that can be used with body armor to carry more gear and better distribute weight. Many other accessories are available to reduce the force of impact and make wearing armor more comfortable, such as trauma pads. Let’s discuss some of the more common accessories for your consideration.

MOLLE/PALS

The PALS (Pouch Attachment Ladder System) was developed in 1997 and adopted immediately for use with MOLLE (Modular Lightweight Loadbearing Equipment) attachments. A little-known fact is what is commonly referred to as ‘MOLLE’ or ‘MOLLE loops’ on plate carriers, belts, backpacks, etc. are actually PALS, as MOLLE refers to the straps on accessories (hence the term “MOLLE accessories”) which are woven in and out of the PALS “Ladder” to create a strong and resilient attachment between the pouch and the carrier. To learn more about these two, check out a detailed explanation in our PALS vs MOLLE article.

Mag Pouches

When it comes to tactical gear magazine pouches are an essential accessories, offering you the means to efficiently carry and access ammunition. Magazine pouches come in various forms, each tailored to specific needs.

What Is a Magazine Pouch?

A magazine pouch is a specialized accessory designed to securely hold firearm magazines. These pouches are crafted from durable materials and are equipped with attachment points that usually adhere to the PALS/MOLLE system. They come in a variety of shapes and sizes to accommodate different magazine types, including those for rifles and pistols.

Benefits of Magazine Pouches:

1. Swift and Convenient Access: Magazine pouches keep your spare magazines within easy reach, enabling quick reloads, and convenient storage.
2. Enhanced Organization: They help you stay organized by neatly storing your magazines, preventing fumbling or dropping rounds when it matters most.
3. Tailored Loadout: The adaptability of magazine pouches allows you to customize your plate carrier to match your specific needs. You can mix and match pouches to cater to various scenarios.

Drawbacks:

1. Added Weight: Carrying multiple fully loaded magazines can increase the overall weight of your plate carrier, potentially affecting your mobility and endurance.

Practical Uses:

Magazine pouches have a range of applications, especially in civilian contexts:

• Home Defense: For home protection magazine pouches ensure you have quick access to additional ammunition.
• Competitive Shooting: In competitive shooting sports, such as IDPA or USPSA matches, magazine pouches are essential to facilitate efficient reloads and maintain a competitive edge.
• Hunting: Hunters often use magazine pouches to carry spare rounds for quick reloading when pursuing game.

Remember there’s a diverse array of pouches available, from single mag pouches designed for pistols and rifles to versatile double pouches (or even triple), often referred to as kangaroo pouches, capable of holding both pistol and rifle mags. Additionally, you can fine-tune your gear further with various specialized pouches, like dump pouches for additional ammo storage or misc. gear, admin pouches for organizing essential notes and tools, and even side plate pouches for more armor protection.

By understanding the nuances of these pouches, you can ensure that every element of your loadout aligns with your unique needs, maximizing your preparedness and efficiency in any scenario.

Tactical Belts

Tactical belts have been referred to as MOLLE belts, duty belts, and even battle belts, and serve as a versatile and strategic addition to your gear ensemble. These tactical belts are designed to offer a convenient platform for essential equipment, all within arm’s reach. There’s a multitude of compelling reasons to include a tactical belt in your kit, such as the option to mount a holster for quick firearm access or carrying a compact Individual First Aid Kit (IFAK) for immediate medical needs.

What sets tactical belts apart is their ability to expand your loadout without encroaching on the limited real estate of a plate carrier. By utilizing MOLLE attachments, you can easily configure your tactical belt to accommodate a range of accessories. Common setups involve attaching pouches for rapid storage, securing an IFAK for immediate medical attention, and positioning spare magazines for swift reloads. Tactical belts provides a customizable and accessible solution to meet your specific needs in the field.

Medical and IFAK

An Individual First Aid Kit, or IFAK is more than just a collection of medical supplies; it’s a beacon of hope in dire situations. This compact yet powerful kit contains essential tools and materials designed to provide immediate care for injuries, ranging from minor wounds to life-threatening traumas. IFAKS have a place on the battlefield, the outdoors, or the challenges of everyday life. An IFAK offers the assurance that you can respond effectively to medical emergencies.

Its compact size and carefully curated contents make it a versatile and vital addition to any preparedness kit. The importance of an IFAK cannot be overstated – it’s not just gear; it’s peace of mind, confidence in the face of adversity, and the potential to save lives, including your own.

An IFAK typically contains a comprehensive array of medical supplies, ranging from bandages and gauze to tourniquets and chest seals. These components are thoughtfully chosen to address various injuries effectively. Additionally, many IFAKs are designed with versatility in mind. They often feature MOLLE or PALS attachments, allowing them to be securely fastened to tactical belts, plate carriers, backpacks, or any gear equipped with webbing.

This adaptability ensures that your IFAK is readily accessible, regardless of your specific loadout or mission. Its ability to seamlessly integrate with your gear makes it an indispensable tool, ready to be deployed at a moment’s notice. So, when the unexpected occurs, you’re never far from the potentially life saving contents of your IFAK. Medical gear may not be as sexy as tactical gear, but it is arguably more important.

Trauma Pads

Trauma pads are crafted from specialized non-ballistic foam. While not designed to stop bullets, they excel at absorbing and dispersing the impact energy generated upon impact. Trauma pads are placed between your hard armor plates and your body, acting as a cushioning layer to absorb and disperse the impact energy of a potential bullet strike. They help with comfort and go along way to mitigate the potentially dangerous effects of back face deformation. 

By providing a cushioning layer between your body and the armor, these pads make extended wear significantly more bearable, ensuring that your protection doesn’t come at the expense of your comfort. So, while they may not stop bullets, trauma pads are essential components that enhance both the safety and comfort of your body armor setup.

Beyond their protective abilities, trauma pads also bring comfort to the forefront, particularly when dealing with single-curve plates and plate carriers lacking internal padding. 

Frequently Asked Questions About Body Armor

Wrapping it Up

Congratulations! You’ve successfully navigated the intricate world of body armor, armed with valuable insights and expertise. As you emerge from this comprehensive guide, you’re not just informed; you’re empowered to make informed choices about your personal safety.

At Tacticon Armament, we understand the significance of body armor in today’s ever-changing landscape. As a leader in the industry, we’ve witnessed firsthand the vital role body armor plays in protecting lives. From understanding the various types of armor and vests to deciphering threat levels and plate materials, this body armor guide has provided you with the knowledge needed to select the right body armor for your unique needs.

Remember, quality matters when it comes to life-saving gear. Don’t settle for anything less than the best. As you embark on your journey to find the perfect body armor solution, we invite you to explore our best-in-class products at Tacticon Armament. With our commitment to excellence and your newfound understanding, you’ll be geared up with the ultimate protection. Stay safe, stay informed, and make the best choices for your individual needs.