Have you ever wondered what goes into making the body armor that protects our brave men and women in law enforcement and the military? At Pivotal Body Armor, we take pride in offering top-quality soft body armor and plates & inserts designed to provide the highest level of protection. Let's take a behind-the-scenes look at how body armor is made.
The History of Body Armor
Before diving into the manufacturing process, it's helpful to understand some background on body armor:
- Body armor dates back to ancient times, with early examples made from materials like animal hides, bronze, and iron
- Modern soft body armor was invented in the 1960s using ballistic nylon
- Hard body armor plates emerged in the 1980s made from ceramics and polyethylene
- Today's body armor leverages advanced materials and rigorous testing standards
Materials Used in Body Armor
Several key materials are commonly used in manufacturing modern body armor:
| Material | Description |
|---|---|
| Kevlar | DuPont's para-aramid synthetic fiber with high tensile strength-to-weight ratio |
| Dyneema | Ultra-high molecular weight polyethylene fiber known for its strength |
| Ceramics | Hard, lightweight compounds like boron carbide and silicon carbide |
| Steel | Hardened steel alloys sometimes used for cost-effective hard armor plates |
At Pivotal Body Armor, we source top-quality materials from trusted suppliers to ensure our soft armor and hard armor inserts meet stringent safety standards.
How Soft Body Armor is Made
Soft body armor is typically made from many layers of woven or laminated fibers. Here's a simplified overview of the process:
- Fibers like Kevlar or Dyneema are woven into a flexible fabric
- Many layers of the ballistic fabric are laminated together using resin
- The ballistic panel is sealed in a protective cover, often with a waterproof layer
- Completed soft armor panels are inserted into a carrier vest
The specific weave pattern, number of layers, and panel design all affect the level of ballistic protection provided by the finished soft body armor. Pivotal offers NIJ-certified Level IIA, II, and IIIA soft armor suitable for different threat levels.
Manufacturing Hard Armor Plates
Hard armor plates provide an extra level of protection against high-powered rifles and armor-piercing rounds. The two main types are metal plates and ceramic composite plates.
Metal Armor Plates
Steel body armor plates are made through a process of heat treating and surface hardening:
- A plate of hard, ballistic-grade steel alloy is cut to size
- The steel plate is heated to very high temperatures in a furnace
- The heated plate is quickly quenched in oil or water to harden it
- The hardened plate undergoes surface treatments and coating
Ceramic Composite Plates
Advanced ceramic plates are made with a complex manufacturing process:
- Fine ceramic powder like boron carbide is mixed with binders
- The mixture is pressed into a mold under high pressure and heat to form a ceramic core
- The core is sandwiched between layers of polymer composite backing material
- The plate is placed in an autoclave for curing under heat and pressure
- The plate is machined to final size, any bevels or edge contouring is added
- A final protective coating such as polyurea is often sprayed onto the strike face
Pivotal Body Armor offers a range of NIJ-certified Level III and IV hard armor plates to defeat high-powered rifles and armor-piercing ammunition.
Body Armor Testing & Standards
Ensuring body armor provides adequate protection requires extensive testing. The National Institute of Justice (NIJ) maintains standards for body armor performance:
- NIJ Standard-0101.06: Establishes protection levels and testing methods for ballistic-resistant body armor
- NIJ Standard-0101.07: Updated 2021 standard with revised test methods and new threat levels
- NIJ Standard-0115.01: Stab-resistant body armor standard
Here are the different protection levels for ballistic body armor:
| Armor Level | Threat Rating |
|---|---|
| IIA | Lower velocity 9mm & 40 S&W |
| II | Higher velocity 9mm & 357 Magnum |
| IIIA | 44 Magnum & sub-machine guns |
| III | High-powered rifles up to 7.62×51mm NATO |
| IV | Armor-piercing rifle up to 30-06 M2 AP |
All body armor sold by Pivotal meets or exceeds NIJ standards. We also conduct our own quality control testing to ensure every product delivers reliable performance.
Proper Fit & Maintenance
To ensure body armor provides effective protection, proper fit and regular maintenance are essential:
- Soft armor should fit snugly against the torso without gaps or bunching
- Hard plates should fully cover the vital organs of the chest with no exposed edges
- Soft armor carriers should be washed regularly and dried completely to prevent mildew
- Hard plates should be inspected for cracks, delamination, or other damage
- Follow all manufacturer care instructions and replace armor by its expiration date
Trust Pivotal Body Armor
At Pivotal Body Armor, we're committed to providing the highest-quality, NIJ-certified body armor to protect those who protect us. From concealable soft armor to rifle-defeating hard plates, our products leverage the latest materials and manufacturing techniques.
When you buy from Pivotal, you can trust you're getting reliable, rigorously tested body armor suited for your protection needs. Check out our full selection of soft body armor and hard armor plates to find the right protective equipment for your role.