We often discuss how to treat wounds caused by bullets or knives, but rarely talk about the prevention of penetrating trauma using body armor. Although a significant investment, body armor can be very effective in hostile environments where there are, for example, areas of civil unrest or, even worse, long-term collapse events. Knowing what kind of armor actually works (and how it works) can literally save your life.
Let’s discuss the different types of body armor, the materials used to make them, and exactly how each one protects the wearer. I’ll keep it practical, because in a crisis you don’t need a PhD in ballistics. For those who do want a deeper dive into ballistic trauma, here’s one of my articles on the subject:
Soft Body Armor
Every type of armor does the same basic job: it robs the projectile of its kinetic force before that energy reaches your vital organs. Soft armor does it by fiber deformation and friction.
For those seeking flexible protection against handgun threats, soft armor is the workhorse if you need to stay mobile. It’s made of multiple layers of high-strength synthetic fabrics—usually aramid fibers like Kevlar or Twaron, or ultra-high-molecular-weight polyethylene (UHMWPE) such as Spectra or Dyneema. These fibers are incredibly strong for their weight; pound for pound, they’re stronger than steel.
Here’s how soft armor works to protects you: When a bullet slams into the fabric, the fibers stretch like a net, spreading the bullet’s kinetic energy sideways through the weave instead of letting it punch straight through your chest. Think of it like a bowling ball landing on a trampoline. The bullet “mushrooms” and the energy is absorbed layer by layer until it stops.
The National Institute of Justice (NIJ) rates soft armor by the rounds it stops. The classic ratings (version 0101.06):
Level IIA: Stops lower-velocity 9mm and .40 S&W rounds.
Level II: Handles higher-velocity 9mm and .357 Magnum.
Level IIIA: The gold standard for soft armor—stops, say, .44 Magnum.
Concealed body armor
Note: The NIJ now has a new rating system (version 0101.07) for handgun and rifle protection levels, explained below.
Soft armor is lightweight (often 5–8 pounds for a full vest), flexible enough to wear under street clothes, and relatively affordable. It has limits, however: It will not stop rifle rounds, and after a few hits the fibers can weaken.
Many vests have a shelf life even if they’ve never been shot. Heat, moisture, and UV light can degrade the fibers over time. Proper storage involves storing body armor flat or on a sturdy hanger in a cool, dry place.
Hard Body Armor Plates
When you need rifle-stopping power, you need hard plate body armor. These are comprised of rigid plates slipped into the carrier pockets of a tactical vest. Hard armor works by shattering, deforming, or eroding the bullet tip so it can’t punch through.
NIJ classic (version 0101.06) rating levels for hard plates are higher than soft armor:
Level III: Stops 7.62 FMJ (full metal jacket) and most common rifle rounds.
Level IV: The highest rifle rating; stops armor-piercing .30-06 rounds.
hard ballistic vest, circa 2013
There are various materials used in the manufacture of hard armor plates:
Steel: Inexpensive, multi-hit capable, but heavy (6–9 pounds per plate) and can “spall.” What’s that? That’s when there are tiny fragments from either the bullet or the armor that can cause injury. Should always be used in combination with a specialized liner or, at least, a trauma pad.
Ceramic (alumina, silicon carbide, or boron carbide): Lightweight at 4-7 pounds, shatters the bullet on impact so the energy is absorbed by the ceramic itself. Excellent against armor-piercing rounds when rated Level IV, but once a plate is cracked by a hit, that area is pretty much done.
Composite/UHMWPE: Ultra-high-molecular-weight polyethylene plates are ultra-light. The plates deform the bullet without shattering. Great for multiple hits, but they can melt or lose effectiveness if, for example, left in a hot car.
A typical setup is a classic Level IIIA (Handgun 2) soft vest for handgun protection plus front and back classic Level IV (Rifle 3) plates for rifle threats. The total weight might be 20–30 pounds, but you’re getting real protection. The plate carrier also lets you carry medical supplies, magazines, and tools, gear you’ll wish you had when the you-know-what hits the fan.
Hybrid and Specialty Armor
Some manufacturers combine soft and hard elements in one vest. Others offer “special threat” plates rated for specific rounds like “green tip” penetrators. There are also stab- and spike-resistant vests made with tightly woven fabrics or chain-mail-like materials. These are especially useful for department of corrections officers and others similarly exposed.
I mentioned the importance of a trauma pad, the soft foam or gel inserts that go behind the plates. They reduces injury caused by something called “backface deformation.” This is the inward bulge that can break ribs or damage organs even if the bullet doesn’t penetrate. Some backface deformation might be inevitable, depending on the bullet and the type of armor used.
It’s important to know that body armor is never 100% foolproof. A bullet that hits at an angle may glance off. Multiple hits in the same spot can overwhelm even Level IV plates. Plus, armor does nothing for your head, neck, groin, or limbs unless you add a helmet, ballistic collar, or extremity armor; that’s a big weight penalty.
NIJ Body Armor Rating: Version 0101.07
The latest version of NIJ ratings is, for some, simpler. It replaces the Roman numeral system for a descriptive one, retires level IIA, and adds a level between classic levels III and IV.
- HG1 (Handgun 1): Replaces Level II. Protects against 9mm FMJ and .357 Magnum JSP.
- HG2 (Handgun 2): Replaces Level IIIA. Protects against 9mm FMJ and .44 Magnum JHP.
- RF1 (Rifle 1): Replaces Level III. Protects against 7.62mm NATO, 7.62x39mm, and 5.56mm NATO (M193).
- RF2 (Rifle 2): Intermediate level. Protects against RF1 threats plus 5.56mm M855 (green tip).
- RF3 (Rifle 3): Replaces Level IV. Protects against .30-06 Springfield armor-piercing (AP) rounds.
Choosing What’s Right for You
There are lots of choices, so which armor is right for your needs? Ask yourself three questions:
–What threats am I most likely to face? Handguns in urban unrest? Soft armor may work. Rifles in a full societal breakdown? Hard plates are the ticket.
–How long do I need to wear it? All day? If so, weight’s an issue.
–Can I actually move, run, and help others while wearing it? You really won’t know until you try it on.
A Level IIIA (HG2) concealed vest under your jacket might be perfect for everyday carry in uncertain times. A full plate carrier with Level IV (RF3) plates, however. is what you want when the grid goes dark and the environment gets hostile.
At the end of the day, body armor is like the tourniquet or chest seal in your medical kit: You (and I) hope you never need it, but you’ll sleep better knowing it’s there. In a world that seems increasingly unpredictable, the prepared citizen who understands both trauma care and ballistic protection is the one who, when things go south, will be most likely to make it home to their family at night.
Joe Alton MD
Read the full article here