Bulletproof Vest Components And How They Work

For those looking for a high-quality bulletproof vest, it can be hugely beneficial to understand more about the makeup and manufacturing process behind these lifesaving pieces of protective wear. This way, you are able to make an informed decision about the type, protective rating, manufacturer, and overall quality of the bulletproof vest that best suits your purposes – this guide serves to help you do just that.

When you decide to make your purchase through Futurama, the quality of your goods is assured. We exclusively stock products like bulletproof vests, plate carriers, ballistic plates, tactical gear, and equipment from the most well-regarded manufacturers in the world – with essential items like these, there can be no compromises on quality. If you are curious about what goes into manufacturing these crucial pieces of equipment, we encourage you to read on and find out more.

Futurama Recommendations

Before diving into the makeup of bulletproof vests, here are three notable mentions from our online store that encapsulate high quality, durability, and versatility.

Zebra Armour Delta 1 Vest With Inners

It would be unthinkable to not include a recommendation from Zebra Protection, as they continually produce some of the highest-quality offerings on the market. The Zebra Armour Delta 1 Vest is characterised by its ultra-lightweight, compact makeup, and impressive IIIA protection rating. Despite being small enough to allow for great mobility, it offers comprehensive front, back, and side protection that should help you come out of dangerous situations unscathed. To add to this, the heavy-duty MOLLE system enables a level of versatility rarely seen with ballistic vests.

Condor Cyclone RS Plate Carrier

If you feel that a plate carrier is more in line with your intended applications, the Condor Cyclone RS Plate Carrier brings a lot to the table. Constructed with Mil-Spec 500 Denier Cordura fabric, with nylon webbing and composite thread throughout, this plate carrier offers unparalleled durability and should no doubt last well into the future. The easy-access pockets allow for on-the-fly changing of plates, and the ability to add medium soft armour only adds to the already immense protective capabilities of this carrier. The quality and performance of this product is undeniable, certainly making it worth your consideration.

Duke Bulletproof Covert Jacket System

If you are looking for a vest that can be easily concealed, the Duke Bulletproof Covert Jacket is a fantastic option. Designed to be worn under thicker jackets or coats, this bulletproof jacket can go completely unnoticed while providing substantial protection from projectiles. This vest is also incredibly light, so light in fact that it can even float in water, and this is helped by its fully waterproof status. Additionally, this covert vest is highly resistant to UV and harsh chemicals, making it almost impossible to accidentally damage the ballistic fibres within. If you aren’t already convinced, it is also stab-resistant and capable of withstanding blows from sharp instruments. This offering is a real all-in-one protection solution.

Essential Components Of A Ballistic Vest

There is no one-size-fits-all approach to modern body armour, and there are quite a few different styles, designs, and materials that manufacturers make good use of. The most common of these materials are steel, Kevlar, Dyneema, polyethylene, or ceramic, and they all serve unique purposes and excel in different areas. With that being said, ceramic and steel are more commonly used in hard body armour, like ballistic plates, although there are vests that implement both soft and hard body armour in the same piece of equipment.

As researchers and companies developed the technology behind bulletproof vests, they discovered that multiple layers of extremely strong fibres offer substantially more protection from projectiles. If the bullet manages to pass through one or two of these layers, there are more directly behind them to ensure the bullet does not go any further.

Each of these layers serve an important purpose, allow us to briefly walk you through them:

1. Outermost Shell: This protective shell is designed to safeguard the sensitive inside layers from the elements, including heat, water, and harsh UV rays. Usually, it consists of abrasion-resistant fabrics like 500D Nylon. This layer is necessary because the ballistic layers beneath are susceptible to damage from outside factors, which can compromise their projectile-stopping abilities.

2. Trauma Reduction Layer: Generally consisting of Mesh EVA Foam or similar energy-absorbing materials, this layer works to spread impacts over a larger region – lowering the chances of blunt force injuries and protecting the wearer from trauma.

3. Ballistic Layer: In past guides, we have touched on ‘bullet mushrooming’ and how essential it is to spread the force of the impact over a broader area. Ballistic materials have an uncanny ability to disperse energy and ultimately, protect the wearer. This layer is the most crucial part of any bulletproof vest, as it is directly responsible for stopping projectiles in their tracks. The most commonly used ballistic material is Kevlar, but Dyneema and Spectra Shield are also becoming more widely implemented in the body armour industry.

4. Backing Layer: The final layer inside a ballistic vest is the backing material, which serves the purpose of providing structural strength, support, and increasing durability. Essentially, it holds all the other layers in place, ensuring that they do not move about upon the impact of a projectile. They are typically created using Aramid fibres or UHMWPE. Some vests may also incorporate a moisture-wicking internal lining for enhanced comfort.

How Is Kevlar Made?

Now that you have a better understanding of the layers that make up a bulletproof vest, let’s get into the manufacturing process of Kevlar. Interestingly, the production of Kevlar is quite similar to the process of making nylon. Firstly, the manufacturer will need to produce substantial amounts of poly-para-phenylene terephthalamide – besides being almost impossible to say, it is also the main chemical used to create Kevlar.

Once enough of this base chemical has been produced, it comes time to begin turning it into strong, singular fibres. This is achieved through a process of repeating amides (chemical compounds that replace hydrogen atoms with carbon-based acid) through which more complex polyamides, like Kevlar, are produced. This is a complicated process of chemical reactions that eventually leads to singular Kevlar strands, now ready to be woven together.

These artificial Kevlar fibres are spun together much like most natural fibres would be, like cotton and wool. This is achieved through a process known as ‘wet spinning’, which turns the basic Kevlar into hardened fibres that can be used in ropes or bulletproof vests. In some ways, the process can be likened to running the hot, concentrated mixture through a shower head that has hundreds, if not thousands, of holes. This leads to many long, thin strands that are then woven together to produce the incredibly strong Kevlar textile.

Kevlar VS Dyneema

We mentioned earlier that there are alternatives to Kevlar, so let’s have a look at how they stack up against the original ballistic material. When it comes to Dyneema, it is almost impossible to come to a straightforward answer about which is stronger between the two. Like Kevlar, Dyneema – also known as UHMWPE – is also a synthetic fibre made up of long polymer chains, but it has a higher strength-to-weight ratio than that of Kevlar.

While this might sound like it is simply stronger or more effective, Kevlar has improved tensile strength over Dyneema – at 3.6 gigapascals, as opposed to the 3.2 of Dyneema. Ultimately, this means that Kevlar is better suited to stopping projectiles, while Dyneema is fantastic when it comes to abrasion resistance and durability. This means that the better option will depend entirely on the specific application.

Dyneema VS Spectra Shield

Spectra Shield is one of the most recent additions to the feasible choices of ballistic materials, and it displays somewhat similar characteristics to Dyneema. They are both classed as UHMWPEs, but Dyneema has a distinct molecular structure from Spectra. It also has a higher breaking strength than Spectra Shield. Additionally, Dyneema has been shown to react more effectively to everyday wear and tear, as well as providing better elasticity. For this reason, most body armour companies tend to opt for Dyneema over Spectra Shield.

Additional Fabrics

We have covered the ballistic materials used in the construction of bulletproof vests, but there are other fabrics used to hold the equipment together. Oftentimes, manufacturers will use Cordura nylon fabrics to ensure structural strength – these fabrics are known for their durability, abrasion resistance, and water repellency, all crucial factors when you consider the impacts these vests need to withstand.

While regular high-strength nylon might do the trick, many companies prefer to go above and beyond to ensure their products are a step above the rest regarding quality. The fact that it is water resistant also makes a difference, as ballistic fibres can quite easily become weakened if they are drenched or submerged. The sides of most ballistic vests are usually made from elastic webbing, while the buckles or closures can be either metallic or Velcro.

Bulletproof Vests And Commercial Use

While we are all familiar with the use of ballistic vests in security work, law enforcement, and the military, many other industries can benefit from the safety this protective gear provides. Before we get into a few lesser-known professions, let’s focus on the three we just mentioned. Security personnel and law enforcement often deal directly with a wide range of criminal elements, and access to bulletproof vests greatly reduces the risk of severe injury.

Nowadays, it is becoming commonplace to provide employees with all the protective equipment they need to perform their role effectively, but also to ensure their safety. Beyond these more obvious lines of work, many industries are beginning to take staff protection more seriously, including paramedics and medical professionals in dangerous locations, firefighters, bodyguards, armoured truck drivers, bank tellers, farmers, and civilians.

You might be wondering why civilians might need bulletproof vests, and the answer is that most people probably don’t. However, if you regularly travel through dangerous locations or live in one, the peace of mind that a bulletproof vest can provide is substantial. Many people have decided to invest in personal protective equipment as an extra safety measure, as we do happen to live in a country with an extremely high crime rate.

In Conclusion

We do hope that you have found this brief guide to be informative – afterall, it can never hurt to know more about the products you are purchasing. If you have not already, have a look through our comprehensive selection of body armour and bulletproof vests, we are sure to have just what you are looking for. If you have any questions, simply send us an email and a member of our friendly team will be in contact with you in no time!