Body Armor 101 - Part 2

In part two of the series, we look at additional factors that impact which armor works the best for your agency and how to optimize its functionality.

Factors that Impact Armor Effectiveness

While body armor is rugged and durable, it’s not impenetrable under all conditions. Several factors determine how well it works beyond just its design.

Moisture – Water can wreak havoc on soft armor. As the fibers get wet, they begin to relax, spread apart, and weaken the overall structure of the weave, allowing gaps in coverage. This is why soft armor is housed in a waterproof carrier that repels moisture. If the waterproof seal is broken, moisture may work its way inside and weaken the weave.

Multiple Hits – While NIJ standards do rate for multiple hits across the face of a vest, most armor is designed to take only one, maybe two shots in a single area. Depending on how close together they are, multiple hits can compromise the integrity of the armor, both soft and hard, as the bullets begin to tear into the structure designed to withstand the impact of only one hit at a time. The first strike compromises fiber or plate strength and weakens the spot, lessening the stopping power if subsequent shots hit the same area. The odds of that occurring are low, but it can happen.

Coverage – Put simply, a vest can’t stop a bullet from hitting an area that’s not covered. The wider the ballistic material, the better chance the bullet will hit it. Be sure any gaps in your vest are closed. This is especially important in two-panel clamshell vests that can leave areas of vulnerability on the sides if not sized correctly.

Wear and Tear – Armor doesn’t last forever. The materials, especially in soft armor, break down over time, and with daily use, that breakdown can accelerate depending on conditions. For this reason, the NIJ recommends inspecting in-use body armor at least once a year.

Ceramic vs. Steel vs. Polyethylene

Hard plates are made from three basic materials: steel, ceramic, polyethylene, or combinations of materials. All are highly effective. Choosing among them comes down to a question of cost vs. weight.

Steel plates are heavier than ceramic but also less expensive. Any unhit areas remain intact and stop additional rounds striking the plate. However, the spall that occurs from impact can send fragments in all directions and can injure the wearer or individuals who are in close proximity.

For this reason, we do not recommend steel plates to our customers. We always recommend other types of hard armor.

Ceramic plates cost a bit more but offer a significant weight savings. This is especially beneficial when carrying lots of other gear, such as extra magazines, a radio, and other equipment often strapped to a plate carrier. Ceramic plates have excellent stopping power. The main drawback to ceramic is its susceptibility to damage not just from bullets but from everyday activity such as dropping it into the trunk of a patrol car.

Polyethylene is a lightweight, plastic-type substance that stops the bullet by using the bullet’s own friction to partially melt the plate and then instantly cool it to wrap the bullet inside, both stopping it from penetrating and reducing bounce and fragmentation. The biggest downside to polyethylene is a lack of level IV protection. It is also somewhat expensive when compared to other types of hard armor.

Which to Choose

Patrol officers and others who wear armor on a regular basis, for hours at a time, often prefer concealable soft armor due to its relatively light weight compared to hard plate armor and slim profile that hides better under a uniform.

SWAT and other tactical teams are less concerned about concealability and more about maximum protection, so they often complement the soft armor with a plate carrier full of higher level stopping power.

Correct Fit

Whichever armor you choose, it needs to fit right to work right. One of the biggest complaints about body armor in general is it’s uncomfortable because it’s either bulky or doesn’t fit correctly. Ill-fitting armor can hinder the mission, or worse, get left at the station or trunk when it needs to be protecting the officer.

Correct-fit armor encourages officers to wear it, increasing the odds they will go home at the end of the shift.

As you consider your armor needs, think less about cost and more about how it will be used.

Learn more about armor basics in Part 1 of this series, where we talk about:

- Types of Amor

- Threat Levels

- NIJ-Compliant vs. NIJ-Certifed