Body Armor Plate Materials
The most common materials used to construct body armor plates include ceramic, steel and polyethylene. Each material has its advantages and disadvantages that should be considered when selecting plates.
Ceramic plates are very strong and can stop higher-powered rifle rounds. However, ceramic is also very brittle and can crack or break on hard impacts. It is important to carefully handle ceramic plates. Ceramic plates tend to be thinner and lighter than other materials but also more expensive.
Body Armor Plate and Steel plates provide good stopping power against many rifle rounds while maintaining durability. Steel armor is less brittle than ceramic but heavier. The extra weight may hamper mobility for some wearers. Scratches or nicks do not compromise the integrity of steel plates like they can with other materials.
Polyethylene, also called polyethylene tetherlene or UHMWPE, armor is lighter weight than steel or ceramic. It stops most pistol rounds and lower-powered rifle rounds. Polyethylene wears down more quickly over time with impacts compared to steel or ceramic. However, it is flexible and shatters instead of brittle cracking like ceramic.
Plate Threat Levels
All body armor plates will be labeled with their threat level ratings indicating the types of ammunition they are capable of stopping. The most common threat levels for plates include:
- Threat Level IIA: Stops lower powered handgun rounds like 9mm and .40 S&W.
- Threat Level II: Stops higher powered handgun rounds like .357 SIG and .44 Magnum.
- Threat Level IIIA: Stops rifle rounds up to 7.62x51mm NATO (aka .308 Winchester).
- Threat Level III: Stops intermediate power rifle rounds like 7.62x39mm and 5.56x45mm NATO.
- Threat Level IV: Capable of stopping the highest-powered rifle rounds including armor-piercing rounds. Level IV plates are usually ceramic or composite materials.
Choosing Plate Cut and Size
Most armor plates are manufactured in one of three cuts: single curve, multi-curve or swimmer's cut.
- Single curve plates are fairly rigid and flat but conform somewhat to the body. They are often used for outer carriers and external plate holders.
- Multi-curve plates more closely fit the natural shape of the torso for increased comfort and mobility. They are better suited for concealed inner carriers under clothing.
- Swimmer's cut plates have an even more ergonomic shape that moves with the body but provide less surface area coverage compared to other cuts. They are suitable for maximum mobility needs.
Plates are available in a wide array of standardized military and LE agency sizes to fit different body types. Sizing charts from manufacturers should be consulted to select properly fitting armor. Oversized plates negatively impact comfort and mobility while undersized leaves protective gaps.
Additional Armor Considerations
Beyond the primary plate, additional protective armor can be added as needed. Some common supplemental armor options include:
- Ceramic or polyethylene strike faces - Provide extra protection immediately behind the main plate from spall and fragmentation. They are low profile for concealment.
- Back plates - Protect the back which is otherwise unarmored. Can be stand-alone trauma plates or connect to a vest system.
- Collar or neck protectors - Defend one of the most vulnerable areas from bullets entering below a helmet.
- Groin protectors - Lightweight protective cups for vital lower abdomen and pelvic regions.
- Shoulder caps - Cover joints prone to injury with a movable armor solution.
- Armor sleeves - Add full arm protection without needing armored shirts or jackets.
Properly selecting a high-quality body armor plate matched to intended threats and form factor needs provides reliable protection on duty or during hazardous activities. Combining a plate carrier system with supplemental armor gives well-rounded safety against a variety of dangers.
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