How does the military use body armor?

• Since the Stone Age, people have been fighting each other for various reasons. Body armor use in military conflict is equally as crucial as tactics and equipment.

  
  

  So, at Bulletproof Zone, we're focusing on that specific topic, from nutshucking contemporary American military gear to speculating on the future of military protective gear.

  
  

  However, in order for you to fully comprehend military body armor, we must go all the way back to the beginning.

• A SUMMARY OF MILITARY BODY ARMOR'S HISTORY

  Metal armor was created for the first time during the Bronze Age. The Assyrians perfected the art of forging iron into weapons and scale armor, and they created the first ever permanent army. They used it to destroy Sumerian city-states and establish a massive empire that lasted for around two centuries.

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• THE ARMS RACE BEGINS IN THE LATE MIDDLE AGES

  Of course, weapons have improved in potency since the swords and spears of Mesopotamia.

  
  

  A sneakier adversary. When 'real' firearms, particularly ranged ones, first appeared around 1400 A.D., that was when things began to change.

  
  

  Since the metal armor of the time just couldn't provide the necessary protection, it was rarely worn during the following 400 years.

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• American Civil War: The Renaissance of Body Armor

  Following its founding in 1775, the American military initially had little confidence in the employment of body armor.

  
  

  Army personnel had to purchase this equipment from peddlers who circulated around army camps and recruitment stations even during the Civil War in the 1860s.

  
  

  The 'Soldier's Bullet Proof Vest,' a normal military vest with front and rear pockets that were concealed with cast iron plates, was the most popular of the hundreds of available versions.

  
  

  Most of them were abandoned by the roadside en route to the battlefield since they were so heavy and thought by many to be unmanly.
  

• World War II: The birth of the flak jacket

  'Battle rattle' was still used sparingly throughout World War I. But when the Flak Jacket was created during the Second World War, everything changed.

  
  

  The 'Flyer's Vest,' which was made of ballistic nylon as indicated by the name, served only to shield the user from anti-aircraft fire.

• The M1 steel helmet helped save countless air force pilots and artillerymen's lives. Over time, flak jackets underwent a number of modifications; Doron fiberglass body armor panels were eventually added and effectively employed in both the Korean and Vietnam Wars.

  
  

  
  

  THE MATERIALS REVOLUTION IN THE SWINGING SIXTIIES

  But it wasn't until the 1960s that materials appeared on the scene that would later change military protective gear all around the world.

  
  

  > At DSM, Ultra-High Molecular Weight PolyEthylene [UHMWPE] was unintentionally discovered in 1963.

  > Around the Vietnam War, American heli crews began using aluminum oxide ceramic plates around 1965.
  

  > Kevlar was discovered the same year entirely by chance.
  

  
  

  The U.S. was inspired by DuPont's new claim to fame. Armed Forces started designing a new type of body armor for the modern era.

• THE DEVELOPMENT OF CONTEMPORARY US MILITARY BODY ARMOR
  

  There are just a few branches of the American military, including the United States Space Force (USSF):

  USA - United States Army
  

  USN - United States Navy
  

  USAF - Air Force of the United States
  

  USMC - United States Marine Corps
  

  USCG - United States Coast Guard
  

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• While protecting the motherland and its interests is their primary duty, each one also conducts their own operations in many domestic and international contexts.

  The U.S. Armed Forces have, in fact, implemented well over a dozen body armor systems over the past fifty years.

  Here, we focus on the important ones:
  

  
  

  PASGT, or Personal Armor System for Ground Troops
  

  The PASGT superseded the flak jacket and M1 helmet when it was introduced in 1983 as the primary body armor for the army, marines, and air force.

  
  

  The PASGT ballistic vest and helmet, in contrast, fit much better. Additionally, they increased side-arm resistance and strengthened protection from shell fragments. A first for American military body armor, the PASGT's body armor helmets and vests were made entirely of Kevlar (ballistic grade K-29).

  
  

• Army reservists continue to utilize the system, while sailors continue to wear the recognizable PASGT helmet.

  
  

  However, there was an urgent need for wearer protection from rifle bullets prior to the last PASGT being turned in. So it was necessary to develop a temporary body armor solution.

  
  

  ISAPO: INTERIM SMALL ARMS PROTECIVE OVERVEST

  
  

  The ISAPO plate carrier, which was imported from early 1996 and worn over the PASGT vest, had front and back pockets into which boron carbide hard armor could be inserted, marking the first time ceramic plates were provided to American ground forces.

  
  

• Despite being able to stop 7.62mm ball bullets fired from powerful rifles, the PASGT vest and ISAPO combination weighed between 21 and 25 pounds and received harsh criticism from American soldiers. Only a small number of ISAPOs were deployed, and in early 2003, they were withdrawn alongside the PASGT.
  

  
  

  IBA: INTERCEPTOR BODY ARMOR

  As the next in line after the PASGT (and ISAPO), the army and marine corps collaboratively built the IBA from the ground up.

  
  

  Despite the fact that the Interceptor Armor roll out began in the summer of 1999, very few were deployed prior to 9/11. After that, before being adopted by the air force and navy, it was regular issue for soldiers and marines.

  
  

  > The following was the core IBA setup: The Outer Tactical Vest [OTV] included three soft armor inserts made of layered Kevlar KM2 that could withstand multiple blows from slugs up to 9mm and shrapnel.

  
  

  > Hard armor plates known as Small Arms Protective Inserts (SAPI) made their debut in the body armor of the United States Armed Forces. The boron carbide ceramic plates may withstand numerous impacts from high-velocity 7.62mm caliber bullets when loaded, front and back, into the OTV and utilized in conjunction with [ICW] the vest's soft armor.

  
  

  Modular engineering was also used to design the Interceptor Body Armor. Both by permitting soft armored add-ons (such as neck, throat, and groin protectors) and by first making its own armor panels detachable.

  
  

• More accessories were made available for the IBA between 2004 and 2006 to provide ballistic protection and widen the protective coverage, including:

  > The Deltoid and Axillary Protector (DAP) is a pair of pads that protects the upper arms, shoulders, and underarms from projectiles and fragmentation.

  > Instead of SAPI plates, Enhanced Small Arms Protective Inserts (ESAPIs) are utilized to stop.Armor-piercing ammunition of 30 caliber.

  > Enhanced Side Ballistic Inserts [ESBIs] are used to defend the lateral torso, which was previously exposed.

  > Protector for the upper legs and back.

  The PASGT/ISAPO system was heavier than the original Interceptor system with complete body armor. However, after adding everything, the weight increased to a stunning 33.1 lbs.
  
  

  One of the reasons the IBA was criticized was that military soldiers also had to carry a lot of other equipment and supplies in their load-out. Other complaints were that the IBA was uncomfortable to wear and restricted mobility due to its bulk.

  
  

  Supporters gushed about the vest's compatibility with MOLLE, which had just been introduced at the time and was used to attach pistol holsters, magazine pouches, grenades, and other gear. Additionally, it featured a large drag handle that allowed a comrade to carry the injured wearer to safety, which, to be fair, did save many American lives during the War on Terror campaigns in Iraq and Afghanistan.

  
  

  The Interceptor Armor dominated the 2000s, and some Army National Guard and Army Reserve units continue to use a small number of them now.

  
  

  IMPROVED OUTER TACTICAL VEST [IOTV]

  The United States Air Force Special Forces [USAFSF] only recently received the IOTV, which was phased in for army units during the second quarter of 2007.

  It serves as an improved alternative to the IBA OTV.

• In response to input from the field, the IOTV is superior to its predecessor in a number of ways, including:

  
  

  1. capacities for protection

  • The IOTV offers comparable frag and bullet protection to the OTV thanks to its Kevlar KM2 and boron carbide ceramic armor.

  • The vest now includes compartments for side plates and a throat protector, and a lower back protector expands the protective surface area by more than 50 square inches.

  • The SAPI/ESAPI plates used by the IOTV and OTV are identical, but the SAPI/ESAPI plate pockets on the IOTV and OTV can be moved up or down to better position the hard armor.

  
  

  2. Weight disparity

  • A fully armored IOTV is significantly heavier (at 35lbs) than an equivalent IBA, but the weight is distributed more evenly across the hips rather than the shoulders thanks to the vests.

  
  

  3. client comfort

  • The IOTV is lined with a breathable mesh cloth in hot weather/climates to lessen heat stress.

  • The Army Combat Shirt [ACS], which is flame resistant and typically worn under body armor vests, is comparable.

  
  

  4. Quick-release device

  • The vest can be quickly and easily disassembled with just a tug on the lanyard, making it a vital means of escape if the user becomes trapped inside a burning car or building, falls into water, or needs medical attention after an injury.

  
  

  5. feminine version
  • The F-IOTV takes smaller, curvier hard ballistic plates and sits higher on the waist. It also features an adjustable corset.

  
  

  
  

  SPS: SOLDIER PROTECTION SYSTEM

  Actually revealed ten years ago, the SPS program aims to increase army mobility and lethality.

  
  

  To do this, it was necessary to develop body armor that was lighter while still providing equal or superior protection than the U.S. Army's current body armor systems.

  
  

  The SPS consists of four separate subsystems:

  
  

  IHPS, or INTEGRATED HEAD PROTECTION SYSTEM

  Both the Advanced Combat Helmet (ACH) and the Enhanced Combat Helmet (ECH) are anticipated to be replaced by the IHPS.

  
  

  The IHPS also has side rails and a Picatinny adaptor for attaching accessories like a headcam, night vision goggles, and comms in addition to passive hearing protection.
  

  The base helmet features increased protection against blunt force impacts and is armored with UHMWPE. The IHPS can be configured into a turret shape to increase head protection by attaching to:

  
  

  > a ballistic helmet.

  > a lower jaw (mandible) ballistic guard.
  

  > a shielding appliqué (cover) that fastens to the top of the helmet shell to protect from sniper fire.
  

  
  

  In addition, the retention method for women can be changed to better fit their hairstyles.

  
  

  MECP: MILITARY EYE COMBAT PROTECTION

  MECP is a brand of ballistic eyewear that has received official military approval for use.

  
  

  TEP: TORSO AND EXTREMITY PROTECTION

  Each TEP component has soft armor comprised of Twaron, Dyneema, and Spectra that shields the wearer from explosion fragments and pistol rounds up to 9mm.

  
  

  [MSV] MODULAR SCALABLE VEST

  The Modular Scalable Vest, which was unveiled in the summer of 2018, will replace the IOTV.

  Fully loaded MSV (in medium size) is a full 26% lighter than the original IOTV.
  

  Initial feedback indicates that the Modular Scalable Vest also offers a significantly wider range of motion, is cooler on the body, and has expanded alpha sizing to fit female men-at-arms with smaller frames.
  

• The MSV is ingeniously adaptable and may be scaled up or down based on the threat and the mission's requirements:

  1. TIER 1 - DISCRETE

  > secret carrier

  > flexible armor panels

  
  

  2. TIER 2 - Low Visibility

  Similar to Tier 1, but with the addition of SAPI ballistic plates.

  
  

  2. TIER 3 - Tactical

  > blatant carrier

  > shoulder armor

  > flexible armor panels

  > SAPIs

  > Hard plates with an Enhanced Side Ballistic Insert [ESBI]

  
  

  4. TIER 4 - FULL SPECTRUM, 

  Similar to Tier 3, but with the Ballistic Combat Shirt added.

  
  

  BCS: BALLISTIC COMBAT SHIRT

  The Modular Scalable Vest is to be worn over the BCS, which was created to replace the ACS.

  
  

  Additionally, there is a variation of the shirt designed just for servicewomen.

  
  

  The BCS has moisture-wicking and flame-resistant fabric in addition to the soft armor components.

  
  

  Unlike the DAP for the IOTV, the deltoid and upper thoracic regions of the body have built-in ballistic protection. The same is true for the arms, upper chest, upper back, upper shoulders, and neck.

  
  

  BPP: BLAST PELVIC PROTECTOR

  BPP is an attachment that covers the thigh and groin area of Army Combat Uniform [ACU] trousers to provide additional protection.

  
  

  B3 - BALLISTIC BATTLE BELT

  To move the load strain from the shoulders to the hips, B3 functions effectively as a standalone Weight Distribution System (WDS).

  
  

  VTP: VITAL TORSO PROTECTION

  The SPS's hard armor component, VTP, consists of its own shooters that can cut ceramic plates.

  > To shield the front and back of the torso, use the ESAPI/X-Threat Small Arms Protective Inserts [XSAPI].
  

  > To defend the sides of the body, insert ESBI/X-Threat Side Ballistic Inserts [XSBI].
  

  
  

  Ballistic threats up to 7.62mm caliber rifle shots can be neutralized when stowed inside the MSV's plate pockets and employed ICW its soft armor. Additionally, a few of the plate sizes were created specifically for women and smaller-framed personnel.

  
  
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• Different SPS subsystems have so far undergone field testing both at home and downrange.

  
  

  Selected army brigades and air force squadrons have received the MSV and VTP from 2017. Additionally, as of 2019, several frontline combat units in nations like Afghanistan, Iraq, and Syria have received the IHPS.

  
  

  MILITARY BODY ARMOR'S FUTURE

  Although the SPS may be the most innovative protective gear for the U.S. Armed Forces to date, it is not the end of the line for body armor. The search for lighter, harder body armor will continue as long as new dangers appear and weaponry become more lethal.

  
  

  Fortunately, our administration keeps investing hundreds of millions of dollars in research and development for body armor for the army, navy, air force, and marine corps. In order to create the next generation of military body armor, the finest and the brightest can continue to rely on developments in materials science and cutting-edge technology.

  
  

  ADVANCEMENT OF CURRENT BODY ARMOR MATERIALS

  Despite Kevlar having long served as the foundation of military soft armor, Ultra-High Molecular Weight Polyethylene is a new ballistic fiber rock star.

  Brazilian researchers have combined UHMWPE boron carbide nanoparticles, which is the newest advancement in the material's refinement. resulting in a possible increase in ballistic performance of about 300%.

  Despite having its roots in the Mongol hordes and being experimented with by the U.S. military in the late 19th century, interest in silk armor has recently had a resurgence.

  Genetic alterations to farmed silkworms' DNA have already produced artificial silk that is at least as strong and elastic as spider silk.

  The Dragon Silk ballistic shootpack panels have since been delivered by the developers, Kraig Biocraft, for the U.S. Army to examine.

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• For the past two and a half decades, with the exception of Dragon Skin, ceramic has been the preferred hard armor for the American Armed Forces.

  
  

  Perhaps the most promising path is ceramic composites, which has the end goal of increasing multi-hit resistance.

  
  

  As we write, experts at U.N.T. who are supported by the Army Research Lab [ARL] are trying with this.

  
  

  NEW POSSIBILITIES FOR BODY ARMOR ARE BEING EXPLORED

  Military body armor can be made from a variety of materials; consider Zylon. But we can never be sure whether something novel will prove to be revolutionary.

  
  

  such as graphene. Technically speaking, it is a single-atom thick sheet of linked carbon atoms in the shape of a honeycomb. The incredibly light substance couldn't withstand being shot at by itself. However, researchers at C.U.N.Y. discovered that by double stacking graphene (also known as diamond), it can change from being flexible to being harder than diamond when pressure is applied.

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• However, scientists at C.U.N.Y. discovered that by double stacking the graphene (also known as dimene), it transforms from flexible to tougher than diamond when pressure is applied.

  
  

  How about armor that can repair itself after being shot? That is much more astounding. The people at the ARL are researching thermoplastics that regenerate as a kind of self-healing armor based on how some animal species may sprout new tissues and organs in reaction to body harm.

  
  

  DEBRIEFING

  Since early man first defended himself with animal hide and bones, we have gone a long way.

  Some types of body armor have already begun to include next-generation materials. However, military officials never stop looking for protective gear that strikes the optimal balance between protection and mobility.

  By doing this, you may contribute to keeping more future members of the armed services safe so they can complete their mission and safely return to their families.

  
  

  Don't leave, though, just yet. Please share your stories about wearing military body armor in the comments box below if you are a current or past member of the armed forces.