Steel vs Polyethylene: Choosing the Best Level 3 Body Armor

Level 3 body armor is designed to protect against most rifle rounds, including 7.62x51mm NATO FMJ. It offers a higher level of protection than level 2A or level 2 soft armor vests. Level 3 plates are rigid and can be made of steel, polyethylene, or ceramic. There are two main types of level 3 hard armor plates: stand-alone and in-conjunction-with plates. Stand-alone level 3 plates provide level 3 protection on their own. ICW plates are thinner and lighter but require a level 2A soft armor backer to reach level 3 protection.

Steel level 3 body armor plates

Steel body armor has been widely used for decades by military and law enforcement. Level 3 steel plates are made of hardened steel alloy and provide robust multi-hit protection against high-powered rifles. Steel plates are the most affordable type of level 3 armor. They are also very durable and can last 20+ years with proper care. However, steel is heavy (7-9 lbs per plate) which can cause fatigue with prolonged daily wear.

Advantages of steel level 3 plates

The main benefits of steel level 3 armor plates include: - Lowest cost (under $150 per plate) - Extremely durable multi-hit protection - 20-year lifespan with minimal maintenance - Thinner than polyethylene (around 0.2") Steel's affordability and longevity make it a popular choice for price-conscious buyers. It can provide reliable hard armor protection for many years.

Disadvantages of steel body armor

There are some downsides to steel armor plates to consider: - Heavier than polyethylene (7-8 lbs vs 2-3 lbs) - Not as comfortable for all-day wear - Potential risk of ricochet/spalling without coating - Can rust if coating is damaged The main drawback of steel is its weight. A complete set of steel plates can add 16+ lbs to your plate carrier loadout. This gets heavy quickly, especially for smaller individuals.

Material	Cost per Plate	Weight (lbs)	Pros	Cons
Steel	$135-$150	8	Most affordable, very durable, thin	Heavy, less comfortable, spall risk
Polyethylene	$400-$550	2.5	Lightweight, comfortable, no spall	Expensive, thicker, 5-year lifespan

What is polyethylene armor?

Polyethylene (PE) is a strong, lightweight plastic material used in hard armor plates. Ultra-high-molecular-weight polyethylene (UHMWPE) fibers are layered into rigid plates for level 3 protection. Popular PE armor brands include Tactical Scorpion Gear and Spartan Armor Systems. These use Dyneema or Spectra Shield PE engineered by DSM and Honeywell.

Advantages of polyethylene level 3 plates

Polyethylene plates offer some significant advantages over steel: - Lightweight at 2-3 lbs per plate - More comfortable for extended daily wear - No risk of ricochet or spalling - Better protection against high-velocity rounds The light weight is the biggest benefit of PE. A full set of PE plates weighs a manageable 6 lbs or less. This makes a big difference in long-term comfort.

Disadvantages of polyethylene body armor

There are some cons to polyethylene armor plates: - Cost 4-6x more than steel ($450+ per plate) - Only last about 5 years - Thicker at around 1" per plate - Can deform after multiple hits Price is the main obstacle for PE plates. They provide great performance but cost significantly more upfront. Polyethylene also has a shorter lifespan of about 5 years.

Choosing between steel and polyethylene armor plates

So which type of level 3 body armor plate is best - steel or polyethylene? It depends on your needs, threat environment, and budget. Steel armor offers reliable protection at the lowest price point. It's a great economical option if weight isn't a major concern. PE armor is ideal if you need to keep weight to a minimum for everyday concealed carry or long shifts on duty.

Compatibility with plate carriers

Make sure to get armor plates that will fit your plate carrier. Steel and PE plates are available in standard sizes like 10x12 shooters cut or SAPI/ESAPI. Look for a plate carrier with an appropriate plate pocket size. If you already have a carrier, measure the pocket dimensions to determine what size plates will fit. Most carriers accommodate both slim steel plates and thicker polyethylene. But it's important to double check sizing first.

Considering comfort and wearability

For extended daily wear, comfort matters a lot. Polyethylene plates are significantly more comfortable than steel. The lighter and thinner profile of PE makes a big difference over long shifts. If you plan to wear plates for multiple hours each day, the extra cost of polyethylene can be worth it. Your shoulders and back will thank you. But for shorter durations or occasional use, steel remains a solid affordable choice.

Budget and long-term costs

Of course, price is an important factor for most people. There's a big difference in upfront cost between steel and polyethylene plates. A set of level 3 steel plates costs around $300, while PE will run closer to $1000+. That's a significant investment, especially on a limited budget. However, it's also important to consider long-term costs. Steel plates can last 20 years, while PE plates should be replaced every 5 years or so. If you plan to use the armor for more than 5-7 years, steel can potentially provide better value over the life of the plates.

Balancing protection and weight

There's always a tradeoff between protection and weight with body armor. Generally, a higher level of armor means more weight and bulk. Steel provides an excellent balance of serious protection and slim profile at an affordable price. But the weight can be hard on your body long-term. Polyethylene cuts weight in half while still maintaining level 3 rifle protection. But you pay a premium for that reduced weight and bulk.

Threat level assessment

What level of protection do you realistically need? Think carefully about the likely threat scenarios you might face. For most civilians and security personnel, level 3 plate protection is more than sufficient against potential assailants. Unless you expect to confront adversaries with armor-piercing ammo, level 3 plates offer solid defense against common rifle rounds.

Multi-hit protection

Both steel and polyethylene plates are rated for multiple hits in a concentrated area. Most level 3 steel plates can withstand at least 3-6 shots from M80 ball ammo. Polyethylene plates stop 6 or more hits on average. This multi-hit capability is crucial, as it's always possible to take multiple close shots in a firefight. Look for nij-tested armor plates to ensure reliable multi-hit performance.

Environmental considerations

Extreme cold or heat can affect body armor performance in some cases. Severe cold can make polyethylene plates more brittle and prone to cracking. Intense vehicle fires could potentially melt or deform PE plates as well. Steel plates don't have those environment limitations. They maintain full integrity and protection across any weather conditions or temperatures.

Spalling and ricochet risk

When a bullet strikes a hard surface like steel, it can cause small fragments to spray out at high speed. This is called spalling and can potentially injure the operator or bystanders. Steel plates often have a spall-resistent coating to minimize this risk. Coating adds cost but provides an important extra layer of protection. Polyethylene plates do not have any risk of spalling on their own. However, a PE plate could potentially deflect a whole bullet at an angle. Anti-ricochet solutions are available.

Maintenance and care

Both types of level 3 armor require some basic care and maintenance. Steel plates should be kept dry and oiled occasionally to prevent rust. If the coating gets damaged, touch it up or replace the plate. Polyethylene plates are generally less maintenance. However, moisture or UV exposure could degrade them over time. Inspect regularly for any deformation or discoloration. Always follow the manufacturer's care instructions for your specific armor plates. Proper maintenance will ensure the armor remains effective and safe over its full service life.

Trustworthy armor brands and suppliers

It's critical to only buy armor plates from reputable manufacturers. Never trust your life to cheap steel or PE plates from an unknown company. Counterfeit or poorly-made plates won't reliably stop bullets. Stick with established armor brands like Spartan Armor Systems, Shellback Tactical, Tactical Scorpion Gear, and AR500 Armor. Look for dealers that only offer certified armor plates, provide clear nij testing data, and stand behind their products.

Beware of marketing hype

Not all body armor is created equal, despite how it may be advertised. Don't fall for exaggerated threat ratings or vague claims of superior performance. If something seems too good to be true, it probably is. Scrutinize armor specifications and testing reports closely. Make sure plates are nij certified to reliably defeat their rated threat level. Even some big-name brands have been caught selling mislabeled plates that fail protective testing. Misleading marketing and bad quality control put lives at risk. Be an informed armor buyer.

Summary: Steel and polyethylene body armor

In conclusion, both steel and polyethylene plates provide true level 3 rifle protection. Steel offers great value and a solid track record at the cost of significant weight. Polyethylene armor is extremely lightweight and comfortable but with a much higher price tag. Evaluate your expected threat environment, daily carry needs, and budget to decide which level 3 plate material is optimal. Buy your body armor from a well-established manufacturer and armor dealer with quality products and transparent testing. No matter which you choose, investing in trustworthy level 3 armor provides priceless peace of mind. Quality plates give you confidence that you're well-protected against deadly threats. If you ever need to armor up, you can trust your gear.

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