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What Is Body Armor Made Of?

There are a ton of different sizes, weights, shapes, and protection levels of body armor. So we often get the question, “what is body armor made of?”

It’s a great question, and knowing the answer can help you choose which options are right for you. We’ve previously discussed this in another blog post discussing the concept of “expiration” of body armor, but we’re going to go a little more in-depth today. If you’ve been looking for something to get a little more in-depth about what it is you’re trusting your life to, we’re happy to help.

Soft Armor: Bulletproof Vests and Flexible Protection

The term “bulletproof vest” is commonly used to describe soft body armor, although it’s not technically “bulletproof.” Instead, soft armor is designed to stop handgun bullets and other lower-velocity rounds, making it ideal for law enforcement, security professionals, and civilians needing discreet protection. The two most popular types of soft armor materials are Aramid and Ultra High Molecular Weight Polyethylene (UHMWPE), each offering unique benefits.

Level II and IIIA Soft Armor

Soft armor is typically classified as either Level II or Level IIIA. This classification tells you what type of ammunition the armor can protect against. Level II soft armor is generally lighter and thinner, making it more comfortable for extended wear but less effective against high-caliber rounds like the .44 Magnum. Level IIIA armor, on the other hand, provides a higher level of protection with thicker layers but may be slightly less comfortable to wear due to the added bulk.

These protection levels are achieved by layering Aramid (commonly known by its brand name, Kevlar) or UHMWPE (known as Dyneema) materials. Each material has strengths and weaknesses, and the number of layers required depends on the specific material properties used. The layers are laminated together to create a flexible yet protective panel that can absorb and disperse the energy of a handgun round.

Aramid vs. UHMWPE

Aramid and UHMWPE materials each have unique properties, making them suitable for different preferences and purposes. Here’s a quick comparison:

  • Aramid (Kevlar): Known for its yellow, woven fabric-like appearance, Aramid is soft, flexible, and affordable. While it’s heavier and thicker than UHMWPE, it is naturally fire-resistant and highly durable. These properties make Aramid a go-to material for applications where comfort and heat resistance are important.
  • UHMWPE (Dyneema): This translucent, white material resembles a stiff plastic sheet. It’s incredibly strong and lightweight, allowing manufacturers to use less of it to meet ballistic standards. UHMWPE is ideal for those prioritizing thinness and lightness. However, it’s more expensive than Aramid and lacks fire resistance, which can limit its use in certain situations.

Some manufacturers combine both Aramid and UHMWPE within a single vest, giving users a balance between weight, flexibility, and cost-effectiveness.

Hard Armor: Rifle-Rated Protection

Unlike soft armor, rifle-rated body armor is designed to stop high-velocity rounds from rifles. Due to the high energy and penetrating power of rifle bullets, hard armor is generally made from rigid materials and configured as a solid plate rather than a flexible panel. These plates are made from materials like ceramics, polyethylene, steel, and composite materials, each with specific advantages and limitations.

Ceramic Plates

Ceramic plates are one of the most popular choices for rifle-rated body armor. They’re made from advanced materials such as Alumina Oxide, Silicon Carbide, or Boron Carbide, combined with a backer material like UHMWPE or Aramid. The combination of ceramic with a backing material helps absorb and distribute the energy from a high-velocity rifle round, making it one of the most effective options for multi-hit protection.

  • Alumina: Alumina Oxide ceramics are affordable and effective. These plates are denser and can handle multiple hits without shattering as quickly as some other ceramic options, making them reliable for prolonged engagements. However, Alumina plates tend to be heavier than others, which can limit mobility and comfort.
  • Silicon Carbide and Boron Carbide: Silicon and Boron Carbide plates are lighter and harder than Alumina, making them better suited for users needing more mobility, such as military personnel. However, these ceramics are more brittle and may be less effective in multi-hit scenarios. Boron Carbide is particularly lightweight and hard, often chosen by high-end users, though its high manufacturing cost makes it expensive.

Ceramic plates balance effectiveness and cost, which is why they’re popular among various users, from law enforcement to military forces. They’re engineered to break upon impact to disperse energy but can maintain structural integrity for multiple rounds with the right design.

Steel Plates

Steel plates are rigid and affordable but come with significant drawbacks, which is why they’re not widely recommended. While steel can provide rifle protection, it’s heavy and prone to fragmentation, where bullet fragments ricochet upon impact, potentially injuring the wearer. New standards prohibit the certification of steel plates without additional protective layers, as they fail to stop common rounds like the 5.56 FMJ used in AR-15 rifles. Steel plates also require add-ons, like fragmentation coating, to reduce the risk of injuries from ricocheting bullet fragments.

UHMWPE Plates

UHMWPE can also be used in hard armor plates. These plates are lightweight, waterproof, and have good ballistic resistance against non-armor-piercing rounds. They’re ideal for situations where mobility and ease of movement are crucial, like in maritime operations or mountainous terrains. However, UHMWPE lacks the strength to stop hardened steel-core rounds, limiting its protective capability against higher-caliber threats.

Composite and Fiberglass-Reinforced Plates

Composite plates, made from materials like E-Glass and S-Glass, provide a low-cost solution for ballistic protection. These materials are similar to fiberglass but are designed specifically for ballistic use, making them much stronger than standard construction-grade fiberglass. Composites offer reliable protection for those needing Level IV protection at a more affordable price, though they may be heavier than high-end ceramics.

Key Considerations for Choosing Body Armor

  1. Protection Level: Knowing what threats you may face is key. Soft armor is ideal for handgun protection, while rifle-rated hard armor is necessary for high-caliber rounds.
  2. Comfort and Wearability: Soft armor like Aramid is flexible and comfortable for prolonged wear, while harder options provide more robust protection but can be heavier and less flexible.
  3. Budget: Aramid and composite materials provide affordable options for different levels of protection. High-end materials like Boron Carbide and UHMWPE are more costly but offer advanced performance.
  4. Environment: Consider your surroundings. UHMWPE plates are ideal for water-based or high-mobility situations, while ceramic and steel options are more suited to urban or stationary environments.

Conclusion

Body armor materials have come a long way, offering diverse options for various protection needs, budgets, and conditions. Choosing the right armor depends on balancing factors like protection level, weight, flexibility, and price. Whether you opt for the comfort of soft Aramid panels, the lightweight protection of UHMWPE, or the high strength of ceramic plates, understanding the materials involved ensures you can make the best choice for your safety.