Body Armor

Military soldiers Standing to control riots Wearing all military gears and riot shield in hand

What is the growth of Personal Protection Market.

We’re living in an increasingly dangerous world, and it’s better to be prepared than to be caught off-guard. Body armour has become a necessity for not only today’s soldiers, but also law enforcement officers and security forces in the civilian sector.

What is the personal protection market?

The personal protection market is another word for the body armour market. The terms encompass more than soft armour vests and hard armour plates; they include ballistic helmets, protective shields, carriers, and other similar products. We recommend a combination of products to maximize your protection and survival chances in any violent encounter.

Key trends and growth areas

Here’s what our professionals at Hardshell are seeing and anticipating in the body armour market.

  1. Emerging economies need up-to-date armour

The military segment holds the largest share of the body armour market, and that share is anticipated to get even bigger over the next five years. However, law enforcement is expected to grow by 5.9%, a high compound annual growth rate (CAGR) in the body armour segment, and as a result should not be discounted.

North America holds the largest market share internationally—bolstered by investment from the military, law enforcement, and federal funding—but other regions are on the rise. The Asia-Pacific region is experiencing the highest growth rate worldwide currently. Countries like China and India have massive active military populations to outfit, and other nations are trying to catch up in both recruitment and equipment.

Most of the major industry players are based in North America, but as other regions grow, more localized companies may see an advantage. Using a local manufacturer allows you to get the best gear possible for your needs and take advantage of professionals’ industry knowledge and recommendations.

  1. Technological advances lead to more investment

New innovative products have created demand. Major manufacturers of all levels are investing in R&D to find more and more advanced materials. Improved survivability is a consistent customer interest, but newer technologies allow customers to get better or equal protection for fewer trade-offs, such as weight, comfort, and coverage.

Liquid armour is one new popular material in the body armour industry. Made notable by the United States Army Research Laboratory, liquid armour uses shear-thickening fluids (STFs) that harden into a solid when forcefully agitated. This allows a flexible material like Kevlar to have the qualities of solid plates when being struck or slashed.

  1. Lightweight armour is on the rise

In part made possible by new technological advances and in part driven by the US Army’s commitment to equipping soldiers with lighter body armour, lightweight armour is becoming more and more popular.

This is not the same as from soft armour, which is also rising in interest among customers. Soft armour is fabric-based and holds up best against knives, pistols, and shotguns. Hard armour tends to use literal hard plates — either made of steel or ceramic — to offer more significant protection in vulnerable spots.

Soft armour shouldn’t be discounted though: not only is it lighter and more comfortable for long-term wear, it covers more of your body and retains your agility. Most law enforcement officers stick to soft armour for daily wear. However, hard armour offers the best protection against a wider range of threats when a user doesn’t know what to expect. Customers expecting their wearers to face military-grade threats are best off using hard armour.

Regardless, in both cases, more and more militaries, law enforcement agencies, and civilian markets are looking for lightweight options in both soft and hard armour. The ideal armour maximizes protection, agility, and comfort for whatever scenarios users find themselves in. Convenience is another factor that more customers are demanding, hence the rise of tactical vests.

Looking to the future

It’s always a good time to invest in your protection. More and more militaries are updating their gear to face asymmetric global threats, and they want a balance between safety and easy wear. To meet these trends, body armour manufacturers need to be nimble and adaptable to their customers’ needs, working to develop materials that offers the best protection and performance for a variety of scenarios.

Working with a company that offers custom solutions ensures that you get the best armour for your needs. As one of the top contract manufacturing companies in the world, Hardshell offers top-of-the-line body armour and accessories to militaries and police forces globally. Our manufacturers are based in Europe, the Middle East, and Asia, making us easy to find and talk to no matter where you are in the world.

Contact us today to talk about your personal protective needs.

Need of Body armor in battleground by hardshell

Do you need any body armor ?

Do you think that you need any thing to protect your self. Do you need  Body Armour

The need for Body Armour can be explained effectively. In recent years World has witnessed a tremendous increase in antisocial activities like terrorist attacks, business or political rivalry etc. This grave situation has made body armour as a basic necessity.

Body armour can prevent unnecessary risk or a life-threatening injury. This is especially a matter of concern for security forces, detectives, correctional forces other associated professionals. Even the workers who work at oil refinery or coal mines may also need to wear body armour at work site. VIPs or politicians also need to wear body armour to protect themselves against any life-threatening attack.

It’s true that more often we shut our eyes and completely ignore the today’s reality and do not pay heed to our responsibility, but body armour has proved to be an only option for ensuring safety.

The United Kingdom’s Health and Safety Laboratory performed a case study ten years back. In this study, a detailed questionnaire was given to over four hundred organisations and then inputs were reviewed. The goal of this study was to understand the need for body armour for a wide range of professionals.

Highlighted Risk Areas:-

* Visiting people in their home or office to enforce laws and regulations, police the system or being the bearer of bad news increases the level of risk and subsequently the need for body armour or stab resistant vests.

* Certain geographical areas or trouble spots are high risk, such as poor or run-down council estates or high crime level areas.

* Dealing with certain high-risk individuals, such as potentially violent or aggressive members of the public, drug users or dealers.

* Dealing with extremely frustrated and disappointed customers (e.g. customers extremely unhappy with the service of your or your partner organisation has provided).

Evicting people from their home.

* Dealing with individuals expressing extreme religious or political views.

* Securing or protecting property, events or people is a professional responsibility that certainly warrants the need for body armour or stab vests.

Enforcing the law.

Many amendments have been done before in rules and regulations associated with health and safety for those people who serve and risk their lives for others. The cost of body armour can never be matched with the cost associated with the severe injuries caused to an employee or the cost associated with the potential Legal action after any incident either being fatal or not fatal in nature. Physical assaults on employees who do not wear body armour create a sense of insecurity among employees and present a bad picture for that employer and his company.

banner with ballistic vest in white background and text - what are bulletproof vest made of ?

What are Bullet Proof Vests Made of ?

Throughout history, people have been protecting themselves from various injuries with different types of possible materials and technologies. In the early days, people used animal skins to protect themselves. As weaponry got advanced, many things got added including wooden and metal shields for their defensive arsenals.

The Making of Bulletproof Vests and The Materials Used

Have you ever wondered how law enforcement officials or security personnel at the line of defense Protects themselves from bullets? They do, however, possess a covert Protection known as a bulletproof vest! They are protected by these innovative suits of armor during hazardous operations or while performing official duties. But what material precisely makes up a bulletproof vest?

In this blog post, we’ll look into the materials utilized in bulletproof vests and the procedure used to make this life-saving equipment. We will also discuss the properties of these materials, and the technologies employed to enhance their effectiveness.

History of Body Armor.

In the 1800s, softer body armor was developed by the Japanese, they used to make the soft armor from silk although the results were quite effective but the cost for same was very high so flak jacket was invented during World War II. It was made with ballistic nylon and used to provide protection from ammunition fragments. Although the Flak jackets were bulky and ineffective against most rifle and pistol fire, but they were widely used, as they provided protection and allowed soldiers to feel secure.

Research and Development

After continuous research and development, In 1960, a new fiber came into the picture which made the Bullet Resistant Vest really Possible and very soon as it was extremely strong and with it, additional waterproofing feature and the layer of fabrics were added which made the vest more durable and wearable. Succeeding the research of fiber, various versions of such Vest got tested by The National Institute of Justice for several years and found that these vests could stop the most common lead bullets: 38 Specials and 22 Long Rifle Bullets.

Modern Body Armor

Body Armour is usually made of Kevlar, Steel, Polyethylene (PE) or Ceramic. Kevlar and PE are used mainly to manufacture soft body armor, whereas steel and ceramic are used to manufacture hard body armor.

The biggest benefit of Kevlar is that it’s way lighter and is much harder and stronger than steel.

Nowadays the Ballistic vests are made up of multi-layers of highly strong fibers which hold and finally deform a bullet, like in the shape of a mushroom. Because of this act, a large fraction of kinetic energy of the bullet or projectile is spread over the large area of the vest fibers. Some layers may be penetrated but as the bullet deforms, the energy is absorbed by a larger and larger fiber area. Although, a vest stops bullet penetration, but still during this course of action the vest and wearer absorbs the bullet’s impulse to cause blunt force trauma which is numerically expressed in terms of back face signature.


Modern Body Armor Designs

Layers of Protection in Bulletproof Vests with Materials Used

Multiple layers make up a bulletproof vest, each of which increases its overall ballistic resistance. The main objective is to reduce the kinetic energy of a bullet and spread it out, which will stop it from penetrating the body. Let’s talk about the many layers that are frequently present in bulletproof jackets:

1) Outer Shell:

The outermost layer of the vest acts as a covering to protect the inside layers from elements including water, heat, and UV rays. It is often constructed from abrasion-resistant fabrics like nylon or polyester.


2) Trauma Reduction Layer:

Located immediately below the outer shell, the trauma reduction layer aids in spreading the force of an impact over a broader region, decreasing the likelihood of blunt injuries. Typically, foam or another energy-absorbing material makes up this layer.


3) Ballistic Material:

The major bullet resistance is provided by the ballistic material, which is the main element responsible for stopping projectiles. The ballistic materials that are utilized in bulletproof vests most frequently are:

Kevlar –

One of the most often utilized materials in bulletproof vests is Kevlar. This synthetic fiber has a remarkable strength-to-weight ratio and excellent tensile strength. Kevlar is an excellent material for body armor since it is lightweight, flexible, and abrasion resistant. The fiber’s structure enables it to efficiently absorb and spread the impact energy of a bullet.

Spectra Shield –

Another material that is frequently utilized in bulletproof vests is Spectra Shield. It is constructed using ultra-high molecular weight polyethylene fiber. Excellent ballistic resistance is provided by Spectra Shield, which is also lighter than Kevlar. Additionally resilient to chemicals, water, and UV rays, the material is robust and appropriate for a variety of situations.

Dyneema –

High-performance polyethylene fiber called Dyneema is renowned for its extraordinary toughness and endurance. Projectiles can be stopped with great success using Dyneema fibers since they are lightweight but stronger than steel. Due to its resistance to chemicals, UV rays, and moisture, Dyneema is a preferred material for bulletproof vests.

4) Backing Material:

The backing material is the bulletproof jacket’s deepest layer. It gives the vest more overall durability, supports its structural integrity, and prevents the ballistic material from deforming under impact. Aramid fibers, UHMWPE, or a combination of the two are often used as backing materials.


Obviously life is priceless and that’s why you won’t take a chance to risk it. We understand that it could be riskier to buy such vital bulletproof vests from other different sources. You don’t have to worry about it if you own a bullet proof vest by Hardshell. Hard Shell is a well-established defense company who have vast expertise of more than a decade in designing and manufacturing body armors. Hardshell produces high-grade quality products to safeguard the life of the wearer and thus you can completely rely on us. Ordering procedures are quite simple and straight forward.


Additional Enhancements in Bulletproof Vests

The makers of bulletproof vests employ new technologies and improvements to increase their capacity to stop bullets. Here are a few of these:

1) Hard Plates:

Hard plates can be added to bulletproof jackets in instances where extra protection is required. These plates can be constructed of ceramic materials or extremely hard steel. These plates, which are usually fitted into the vest’s pockets, provide improved resistance to high-velocity rifle bullets.

2) Soft Armor panels:

These can be incorporated into the design of the jacket and are often constructed of aramid fibers or UHMWPE. Without limiting mobility, these panels extend coverage to crucial regions including the sides, shoulders, and collar.

3) Multi-Hit Capability:

A modern bulletproof vest is made to endure a number of blows without losing any of its defensive qualities. The effectiveness of these vests is maintained even after stopping numerous shots because of their multilayer design and specialized ballistic materials.

4) Stab and Spike Protection:

Some bulletproof jackets include layers or inserts that are specifically made to resist punctures from sharp items like knives or ice picks in addition to ballistic protection. Materials such as laminated Kevlar or metal alloys are frequently used to create these additional layers.

Manufacturing Process of Bulletproof Vests

Now that you know about the layers of protection in a bulletproof vest and the materials used, let us discuss the manufacturing process of bulletproof vests.

1) Design and Pattern Making:

Designing and pattern making are the first steps in the production of bulletproof vests. Together, designers and engineers develop a vest pattern that offers the best possible defense while maintaining the wearer’s comfort and mobility. Choosing the quantity and location of protection panels at this phase requires taking into account the particular ballistic threats the vest is made to endure.

2) Material Selection and Cutting:

After the pattern is decided upon, the right materials are chosen in accordance with the desired level of protection. According to the pattern, Kevlar, Spectra Shield, or Dyneema layers are cut into the necessary shapes and sizes. To maintain accuracy and consistency in the cutting process, manufacturers frequently employ computer-controlled cutting machines.

3) Layering and Assembly:

The protective panels are created by layering and assembling the ballistic fabric that has been cut into layers. These panels are made up of several layers of the selected material, each of which is orientated differently. This configuration improves the vest’s capacity to efficiently dissipate impact energy. Frequently, adhesive bonding methods or a mix of heat and pressure are used to join the layers together.

4) Sewing:

High-strength threads are used to sew the panels together after they have been put together. Heavy-duty sewing machines able to handle the thickness and density of the ballistic materials are used during the sewing process. To guarantee the integrity and durability of the finished product, careful consideration is paid to sewing techniques and thread tension.

5) Finishing touches:

After the vest’s primary assembly is finished, extra parts like straps, fasteners, and closures are added. For the wearer, these components offer adaptability and a snug fit. To enhance comfort, ventilation, and ease of movement, manufacturers also use ergonomic features and design components.

6) Testing and Quality Control:

A crucial step in the manufacturing process is quality control. Each bulletproof vest is put through extensive testing to make sure it satisfies the necessary safety requirements and ballistic resistance levels. In these testing, the vest is frequently subjected to simulated ballistic strikes with firearms while the amount of damage is measured.

Bulletproof vests serve as a symbol of our dedication to the safety and well-being of people who protect and serve our communities. These equipment are also a testimony to the creativity and dedication used to provide life-saving protection to those in high-risk professions.

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    Female police officer shooting on black police body armour

    13 Police Body Armour Details You need to Know | Police Body Armour Guide

    Since the beginnings of organised warfare, soldiers’ personal equipment has included body armour. The earliest evidence of armour is from the third millennium BC, although there is evidence of offensive weapons dating from the eighth millennium BC (Hackett, 1989), so the history of armour is likely to be comparable.

    The tremendous knowledge gathered over thousands of years led to a range of highly effective armour systems, despite the fact that the development process was virtually entirely empirical.

    New advancements such as high-strength synthetic materials have built on this to create systems that protect wearers from bullets, shell fragments, and knives.

    Body armour is now an necessary element of everyday wear for both military and police personnel as a result of these improvements.

    What is Police Body Armour?

    One of the most prevalent pieces of safety equipment used by cops is body armour.

    A few hundred police officers are assaulted each year. A lot of people’s lives are saved by wearing body armour. Body armour also provides additional protection for police personnel in the event of car accidents or other types of assaults.

    The majority of police body armour and helmets are designed to protect officers from pistol threats. Although police helmets are not as popular as body armour, the criteria for helmets require that they stop comparable bullets. To defeat rifle shots, law enforcement obtains a limited supply of body armour with breast plates.


    The need for Police Body Armour:

    It encourages the use of personal body armour by documenting the armour’s effectiveness to reduce mortality and disability.

    It recognizes individuals who have survived a life-threatening situation as a result of wearing personal body armour.

    It also serves the law enforcement community by gathering and disseminating critical information about these survivor incidents.


    Why do police officers wear soft body armour?

    Hard body armour and soft body armour are the two types of modern body armour. Metal or ceramic plates are used to make hard body armour. The majority of soft body armour is made up of layers of fabric made of high-performance fibers.

    Soft body armour is mostly employed by soldiers on the battlefield in conjunction with hard body armour to provide adequate ballistic protection, or by law enforcement officials who are more likely to confront lesser levels of ballistic hazard.


    The need for Body armour for police dogs:

    The UK’s police dogs are outfitted with a lightweight custom-made armour that is designed to protect them. This is available for both general purpose and drug dogs.


    ballistic protection products used by Police

    How is the Police body armour made?

    The Police Service employs a diverse group of officers who serve in a variety of capacities. Each has its own set of responsibilities. Stabbing proof vests are the most basic protection equipment necessary for many police officers. This isn’t because they are widely being used, but because they are the most widely available weapon.

    A bulletproof vest is made up of a panel. It is a vest-shaped sheet of modern plastics polymers made up of numerous layers of Kevlar, Spectra Shield, or Twaron (similar to Kevlar) or Dynema in other nations. The woven Kevlar layers are neatly stitched together using Kevlar thread, whereas the nonwoven Spectra Shield is coated and bonded with Kraton resins.

    The panel here offers protection but not much in the way of comfort. It is enclosed in a fabric shell, which is often constructed of a polyester or cotton blend or nylon. Sewing a sheet of absorbent material, such as Kumax, on the side of the shell facing the body makes it even more comfortable. The Nylon padding can be included in a bulletproof vest for further protection. Built-in pouches are also included in bulletproof vests designed to be used in particularly risky conditions.


    Why do police officers wear soft body armour?

    Hard body armour and soft body armour are the two types of modern body armour. Metal and ceramic plates are used to make hard body armour.

    Most of the soft body armour is made up of layers of fabric made of high-performance fibers. Soft body armour is mostly employed by soldiers on the battlefield over the hard body armour to provide adequate ballistic protection, or by law enforcement officials as they are more likely to confront lesser levels of ballistic hazard.


    What are the threats from ballistic missiles and material requirements?


    Bullets fired from handguns or rifles, and pieces from artillery shells or bomb blasts, are called as ballistic hazards. Bullets can be easily formed of a variety of materials and shapes, depending on the end-use application.

    Bullets that are made of pure lead with a hemispherical head are highly prone to bend but have fewer penetrating capabilities. This causes the most harm to the human torso. The ones having a metal covering and ogival head proved to have less deformation during an impact occurrence. This even resulted in less blunt tissue trauma.

    Deformation and penetration of fragments are highly influenced by the shape and impact velocity of the pieces, both of which are difficult to forecast. To avoid distortion during a ballistic shooting test, penetrators are usually composed of hardened steel. The impact velocity can be changed to suit the needs of the test.


    To design protective and lightweight body armour, it is necessary to understand ballistic risks. There are a number of conditions that should be met by the materials used in police body armour design:


    body armour and hard armour plates


    1. Materials should be really strong enough to give adequate ballistic protection to wearers.

    2. Lightweight and low-bulk materials are necessary, this comes with the goal of not impeding the wearer’s mobility and efficiency.

    3. Materials used should be long-lasting, ensuring that body armour’s performance does not deteriorate under adverse conditions such as moisture or UV light.

    4. To give enough comfort, the materials should be super flexible.


    Levels of Police body armour:

    The Body armour is divided into five categories: Level IIA, Level II, Level IIIA, Level III, and Level IV.

    This has been established by the National Institute of Justice (NIJ). The National Institute of Justice (NIJ) is responsible for creating and defining designations. Type IIA bullets were tested in 9 mm Full Metal Jacketed Round Nose (FMJ RN) and.40 S&W Full Metal Jacket (FMJ) calibers.


    Level II:      Type II bullets are tested in 9 mm FMJ RN and.357 Magnum Jacketed Soft Point (JSP) calibers.

    Level IIIA:  Type IIIA rounds are tested in.357 SIG FMJ Flat Nose (FN) and.44 Magnum Semi Jacketed Hollow Point (SJHP) calibers.

    Level III: Hard armour or plate inserts tested with 7.62 mm FMJ steel jacketed bullets in Type III (Rifles).

    Level IV:   Hard armour or plate inserts were tested with.30 caliber armour piercing (AP) bullets in Type IV (Armour Piercing Rifle).


    Nij Protection Levels As per Bullets Specification Chart

    Impact and ballistic protection of Police body armour:


    The modern body armour is divided into two sections:

    A ‘soft’ vest that protects against fragmentation and ‘hard’ plates that defend against armour-piercing gunfire.

    To shield a body part from impact, the protective layer should be immediately over it at the time of impact. To put it in a simpler way, well-fitting armour is snug and secured against the body at all times. The most effective way for body armour to work is for it to be specifically shaped to the individual’s shape.

    Even when money was not an issue, making personalized armour for each individual would be impracticable. It would also be impossible to keep up with the natural changes in an individual’s body structure over time, as well as personnel turnover.

    Only a few such as two to five sizes of body armour are available to accommodate a wide range of torso shapes and sizes. This is primarily because of the high cost of ballistic materials and the production process. Also, the number of sizes was chosen to provide more economical protection rather than the optimum protection.

    Just like the medieval steel breastplates, early plate designs emphasized protection over mobility. It aimed at covering the full front and much of the sides of the body as feasible.

    Body armour now consists of simple rectangles aligned longitudinally with a concave inner surface, and modern plate designs prioritize mobility over protection. The rigid plates were supposed to protect crucial organs while also allowing for the shoulder and arm motion.

    Sizing and fit must rely on adjustability characteristics when there are so few sizes. The present soft armour vest is designed with limited torso circumference and strap length adjustment.

    As the hard body armour plates are frequently installed inside the soft armour vest fabric pocket, it may or may not cover all important organs. It also depends on the wearer’s body size and how the strap length has been adjusted.

    Body armour for law enforcement Police officers has gone through multiple advancements over the decades. While these have made the latest armour significantly lighter, more reliable and stronger, it should be noted that bulletproof armour is typically rated up to certain protection levels and may not stop all types of ammunition. There are now overt and covert types of body armour and are selected according to the situations and protection levels the officers are placed in.

    Advanced Materials:

    Metals were the most commonly used in Police body armour material in earlier versions, but was quite heavy, although being effective. As the maneuverability and speed of law enforcement personnel also matter a lot in their roles, metals were slowly replaced by new-age materials such as composites. One such high-performance material is called Aramid, which when woven into a fabric form, becomes bulletproof. Another material is called Ultra High Molecular Weight Poly Ethylene, commonly abbreviated as UHMWPE.

    Different Situations:

    Law enforcement officers use different types of Body armour according to their roles in the force. Patrol officers prefer bulletproof armour while those on prison duty prefer spike & stab-proof armour. Although these types of armour are built to be tough, the specific variant should be selected based on the perceived threat during its application.

    Protection Levels:

    According to the threat levels in different situation, the protection levels offered by body armour also varies. Protection levels vary from Level II, Level IIIa, Level III and up to Level IV. Level II and IIIa provides defense against commonly used ammunition such as 9mm upto .44 Magnum, while Level IV protects against larger rounds such as those used in Sniper rifles.

    Level IIIa is the most common type of body armour for regular law enforcement officers, while Level IV is only used in Special Forces such as SWAT teams.


    Generally, all body armour manufacturers specify guidelines on maintenance of their products. Some of the basic points include, but are not limited to:

    • Carrier vests alone can be machine washed, once the armour plates are removed
    • Keep the armour plate away from direct UV radiation
    • The armour panels themselves can be wiped with a wet cloth or sponge, and should not be immersed in water


    Which is the Best Police Body Armour?

    Here are top three body armorus used in United States:

    ●  BodyArmorDirect Freedom Concealable Multi-Threat Vest

    The BodyArmorDirect Freedom Concealable Multi-Threat Vest is an NIJ-certified concealable vest created in the United States on sewing machines at a facility in Florida.

    This is a stand-alone body armour vest with no extra inserts or plates required.

    A 100 percent woven layer of aramid fibres protects the torso, sides, and back, providing Level IIIA ballistic protection for most handgun threats up to.44 Magnum.

    ●  Premier Eagle Tactical Vest with Level IIIA Soft Panels

    The Eagle Tactical Vest is a tactical vest with NIJ-certified Level IIIA soft ballistic plates made by Premier Eagle, a well-known manufacturer of body armour and ballistic protection products. This product protects your essential organs from the majority of firearm attacks from all sides.

    This device is ideal for law enforcement, security, and bodyguarding, but it can also be used by anyone looking for high-quality ballistic protection.

    ●  AR500 Armor Standalone Ballistic Steel Plate Level III+

    AR500 Armor is one of America’s most well-known producers of hard armour plates and steel shooting targets. The corporation is called after the same-named type of abrasion-resistant steel. Steel armour plates outlive all soft materials like Dyneema or aramid, and are more resistant to impacts and abuse than ceramic materials.




    Military Tan Multicam Print body armor side view



    In early 2000’s , US army  used  to  incorporate the Interceptor Multi-Threat Body Armor System (IBA) as a bullet-resistant vest for  the United States Armed Forces, with some limited usage into the mid-2010s. The IBA and its design replaced the older standardized fragmentation protective Personnel Armor System for Ground Troops (PASGT) body armor system that was designed in the late 1970s and introduced in the early 1980s.

    The IBA system consisted of its core component: the outer tactical vest (OTV), which can optionally be worn with a throat protector, groin protector, and bicep (or deltoid) protector. The latter three auxiliary protectors are removable from the main vest, which can be worn alone. Beginning in 2007 the Improved Outer Tactical Vest began to replace the IBA in the United States Army’s service and since then it has been mostly replaced in its inventory, with the exception of a few IBAs still in service with the Army National Guard and U.S. Army Reserve.

    IOTV (Improved Outer Tactical Vest)

    The Improved Outer Tactical Vest (IOTV), is an enhanced version of, and a replacement for, the older Outer Tactical Vest (OTV) variant of the Interceptor body armor, as fielded by the United States Army. The IOTV is compatible with the Deltoid and Auxiliary Protector System (DAPS) components, ESAPI (Enhanced Small Arms Protective Insert), Enhanced Side Ballistic Inserts (ESBI), as well as the OTV’s groin protector. The IOTV is currently produced by Point Blank Body Armor, BAE Systems, KDH Defense Systems, Protective Products Enterprises, UNICOR and Creative Apparel Associates. The IOTV first saw action in combat with U.S. Army ground combat units in from mid-2007 onward and currently remains the standard body armor type used by regular U.S. Army ground combat units overseas.

    A size Medium IOTV weighs 3.6 pounds (1.6 kg), less than a Medium OTV vest, while providing more coverage. However, a fully equipped IOTV, complete with all its components (soft armor panel inserts, four ballistic plate inserts (front and back plates and two side plates), collar, and groin protectors) still weighs 30 pounds (14 kg), with a Large IOTV weighing about 35 pounds (16 kg). The functionality of the enhanced side ballistic inserts, which provide coverage under the arms and down the sides of the torso, is built into the IOTV. The IOTV provides the ability to don the vest in two ways. The first is to simply place the vest over the head and pull down, and the second is to remove fasteners on the wearer’s left shoulder, sliding into the vest to the right. To complete the procedure for both methods the wearer then lifts up the front panel of the vest and fastens the waistband, which takes the weight of the vest off the shoulders somewhat, and then fastens the side protection modules. A key design feature for the IOTV is that the entire armor system is able to be released with the pull of a hidden lanyard. The armor then falls apart into its component pieces, providing a means for escape in case the wearer falls into water or becomes trapped in a hazardous environment. The hidden release lanyard also allows medical personnel easier access to a casualty, which was one concern that was not addressed with the old Interceptor armor.

    Source :- Wikipedia

    More Body Armor Designs


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      Camouflage Patter Bulletproof vest in white background

      How to Buy Bulletproof Vest in 2023

      Bulletproof vests are essential protective gear for individuals working in high-risk professions such as law enforcement, military personnel, and security personnel. With the increasing prevalence of violence and crime, it has become crucial to invest in a reliable and effective bulletproof vest. However, choosing the right vest can be a daunting task, as there are numerous options available in the market. This article aims to provide a comprehensive guide on the key points to consider while purchasing a bulletproof vest. By understanding the various factors that contribute to the effectiveness and durability of these vests, individuals can make an informed decision and ensure their personal safety in the face of potential threats.

      Ballistic Material Used :

      Ballistic vests are made up of multi layers of highly strong fibers which catch and finally deform a bullet like in the shape of mushroom. Because of this act, a large fraction of kinetic energy of the bullet or projectile is spread over the large area of the vest fiber. Some layers may be penetrated but as the bullet deforms, the energy is absorbed by a larger and larger fiber area. Although, a vest stops bullet penetration, but still during this course of action the vest and wearer absorbs the bullet’s impulse to cause blunt force trauma which is numerically expressed in terms of back face signature.

      Material like nylon or Kevlar, Twaron or Spectra or polyethylene fiber, either laminated or non-laminated can be used to manufacture bullet proof vests. From these fibers, yarns are made out which are later turned to cloth or panel or fabric by weaving machines. Finally these ballistic panels are then sewn together with shells (cover) and other accessories like straps.


      NIJ Protection Ratings

      National Institute of Justice gives the rating for the body armour the ratings range from IIA to IIIA for soft body armor. These ratings are based on the intensity of the blunt force, exerted by projectile, that can withstand and stopped by the body armor. This is applicable for both stab resistant and ballistic resistant body armor.

      The vest whose NIJ standard ratings are:  IIA, II, and IIIA come under the category of soft body armors. They are made to stop bullets from small fire arms. These are very lightweight and thinner vests.  These three vests are recommended if you are likely to encounter small arms fire. Thus these vests are suitable for civilians who are not in war zone. However, for advanced protection required by soliders in war zone, Level IV vests (hard body armour) are needed.

       IIA vests can stop bullets from a 9mm or .40 caliber handgun, II vest can stop 9mm and .357 caliber handgun bullets, while IIIA vest can stop larger caliber handgun bullets like a .357 SIG and .44 Magnum. On other hand level IV vest can save you from .30 caliber armor piercing rounds.


      legality of owning or Wearing Bulletproof Vest

      It is important that one should be well aware of the local laws or regulations that are associated with the purchase or usage of body armors. Generally, in almost many countries, it is illegal to purchase or wear body armors in the case if the person has been convicted before or has a criminal background. Thus there is a need to abide the local governing rules and get a permit to buy or use such body armors.




      • Note down weight and height of the user
      • Wear tight fitting clothes (for concealed vest) and uniform (for external vest) for measuring chest or torso sizes.
      • Measure the size of chest and the widest part of torso (while relaxing the muscles and breathing normally). Round off the measured value to nearest whole number. For instance, if the measured size of chest comes out to be 41.1 cm, round off it to 43 cm.
      • To get the required length of vest, measure the distance between center of collarbone and navel.
      • Compare the body measurements and desired NIJ level with that of the specifications or dimensions given by the manufacturer.


      While purchasing the vest by online or offline mode, user is advised to try different physical postures and activity while wearing the vest so as to ensure that the vest is comfortable for the wearer.


      Replacement Policy / Warranty Policy

      Replacement becomes important in every five years or when vest is shot by the projectile as a result of which ceramic plate (in case of HAP) gets cracked or broken. Get a replacement vest every five years or after it gets hit with a bullet.


      Where You Can Buy Bulletproof Vest

      With a strong global presence, we are dedicated to providing top-notch products that meet the highest standards of safety and protection. Our team of experts is committed to understanding and meeting your specific requirements. Whether you are a law enforcement agency, military organization, or security professional, we are here to assist you. Please feel free to reach out on Email  or Contact us


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