Types of Armor

The two most common types of armor are “soft armor” and “hard armor.” Soft armor is commonly found in concealable armor, such as our 4PV and 4PV-FEM, the types of vests worn underneath a uniform shirt. These panels are made out of either tightly woven aramid threads, such as Kevlar or other similar material, laminates such as Dyneema, or a combination of the multiple types of these fabrics. Soft body armor does not deflect or repel bullets. Instead, it catches the bullet within the weave to dissipate the energy and prevent it from penetrating.

Hard armor is harder and thicker, commonly made from either steel or ceramic, and usually backed with pressed laminate. Each has its advantages and drawbacks. Hard armor is designed to shatter the round, dispersing the energy and preventing penetration. Many armor plates have an extra layer on the outside to reduce fragmenting.

While soft armor tends to be fairly lightweight and suitable for everyday wear, hard armor is heavier, so it is reserved largely for tactical vests and any application where the wearer will have it on for a relatively short period.

Threat Levels

Body armor, either soft or hard, is designed to stop only certain types and calibers of bullets.

The National Institute of Justice (NIJ) sets the standards for “threat level,” the measure of stopping power based on the caliber and velocity of the projectile.

Threat levels fall into five categories: IIA, II, IIIA, III, and IV. Each higher category protects against higher-level threats than the previous one.

Concealable soft armor typically rates to level II or IIIA, designed to stop pistol rounds. Hard armor plates rate as high as IV, tested to stop certain types of armor-piercing rifle ammunition.

NIJ-Compliant vs. NIJ-Certified

The NIJ not only sets ballistic armor standards, it also runs an extensive testing program and encourages manufacturers to submit their armor panels, both soft and hard, for testing at their facilities. The test includes not only ballistics tests to determine threat level, but also endurance tests, such as immersion the armor in water for 30 minutes and a high-humidity/high-heat test to see how well the fibers hold together under adverse conditions. Armor that passes official NIJ laboratory testing is labeled as “NIJ-certified,” the highest rating that armor can achieve. Because it is so thorough, NIJ testing is a long and expensive process.

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.

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.