Kevlar vs Steel vs PE Body Armor (2024)

Kevlar, steel,Polyethylene (PE)and ceramicarefour commonmaterials inbody armor manufacturing. In this handy guide, we'llexplore each of these materialsand when they're most suitable. So, sit back and relax as we take you through the exciting journey of body armor comparisons — you'll probably be an expert by the time we're done.

Ceramic

First, we'll explore the pros and cons of ceramic body armor plates.

Pros

Ceramic platesaretypically about 37% lighterthan steel plates andcheaper than PE, typically costing under $200. They're generally good forfive to seven years— provided that they don't take a bullet, obviously — which is a pretty impressive life span for their price and fragility.

Consider ceramic body armor if the following pros are most important to you:

• Light, mobile and concealable
• Relatively long-lasting
• Less expensive than other materials

Also classified as hard body armor,they can offer equal protection as steel plates in some cases. All things considered, they might seem like thetop choice right off the bat.

Cons

Ceramiccannot takeprecision fire, ormultiple shots to the same spot. Though theplatewon'tcompletely shatter into pieces, the spothit cracks badly, or completely shatters the roughly one-inch diameter tiles in that area.That platethenbecomesineffective, as it'salmost certainthe bullet will go throughwhenhit at the same spot again.

They'reideal if you're certainyouwon'tbe facing heavy gunfire threats— but you'd better know that for sure. When considering ceramic vs. steel body armor, for instance, you'd likely pick steel if there's a chance you'll face precision fire on the job.

Let's recap the cons of ceramic armor:

• Cannot withstand heavy or precise fire
• Prone to cracking

Polyethylene

Next up is Ultra-High-Molecular-Weight Polyethylene. Thankfully, the name is usually shortened to polyethylene, or PE, which is much less of a mouthful. Considered a type of hard body armor,PE body armoris often placed in acarrier vest.

While it'salmost as hard as steel,it weighs less and provides greater comfort for the wearer. A plate constructed from PE generally weighs between 2 and 5pounds, making itthe lightest rifle-protective plate available.

Pros

PE armor plates can take multiple hitswithout shattering, provided thebullet threat is not above level III. Thematerial qualityand manufacturing processboth contributetothiseffectiveness.When the UHMWPE sheetsare subjected to high pressure and form a perfect bond,the platecanwithstand multiplerounds.

This characteristic makes it a favorite among military personnel, law enforcementand civiliansalike.Another glowing benefit of PE is that while it's the lightest type available, it's also15 times strongerthan steel.

To recap, here are the overall pros of PE body armor:

• Lightweight and comfortable
• Withstands multiple rounds
• Stronger than steel
• Will not cause bullets to shatter and create shrapnel like steel plates

Cons

PE armor platesweaken when exposed to extremely high temperatures (158 F). For military personnelworkingin hot regionslike deserts, for instance, the environmentalconditions could theoreticallylimit PE'seffectiveness.Otherwise, PE armor plates areincrediblydurable.

Additionally, PE body armor is more costly than other materials due to its expensive composition and manufacturing process. When weighing steel vs. PE body armor, for instance, you'd probably opt for steel if you want the lower-cost option.On average, PE plates are200%-300%more expensive (but also 200%-300% lighter than steel) than ceramic or steel — pretty steep, we know.But if you're willing to spend the extra dough and won't be spending time in the desert, PE is an excellent investment.

The main cons of PE armor are:

• Lower tolerance when above158 F
• More expensive than other plate options

Steel

Steel ballistic plates are arguably the most popular steel body armor products. They'reused in conjunction with carrier vests, which are made of regular fabric. The plates are inserted into specially designed pockets within the carriers.

Pros

A steel ballistic platecan perform well incirc*mstances involving rifle fire, as it may helpsubdue blunt trauma.Perhaps its most impressive quality is that it can takemultiple bulletstothe same spot.

Another major advantage is that steel body armor has a longer shelf life than other materials. We find that it can last between 15 and 20 years on average, while other types generally span five to seven years.

Consider investing in steel armor if the pros below are most important to you:

• Withstands precision fire
• Subdues blunt force trauma
• Exceptionally long shelf life

Cons

Becausesteel is a heavy material,thebody armor will feel bulky.Therefore,civilians and uniformed patrol officersmay find itdifficult to conceal and move with steel armor.For that reason, it's more popularwith third-world tactical forces facing rifle gunfire threats.

Another drawback to steel plates is that they can cause bullets to shatter, creating shrapnel that may ricochet and result in serious injury. Other materials like ceramic and PE are more effective in absorbing force and deforming a bullet, making them safer alternatives to steel plates.

The overall cons of steel body armor are:

• Heavy, bulky and less comfortable
• Difficult to conceal
• Can shatter bullets and result in injury

Kevlar

Kevlar is made from a material calledpolyparaphenylene terephthalamide— don't worry, we can't pronounce it either. Producers make Kevlar in sheets or mats by heating the polymer and forcing it through a sieve to create stiff, high-tensile fibers they can weave together.

Pros

Kevlar has more than just a cool-sounding name — there are other impressive qualities to consider as well.Kevlar’s molecules are unidirectional and parallel to each other.They're alsotightly bound,resulting inhigh tensile strength.

Despite being a lightweight material, Kevlar isfive to six times strongerthan steel.If you need comfortable, flexible armor that can provide everyday protection against ballistic, physical, stab and slash hazards, Kevlar can deliver. Since Kevlar is a synthetic fiber,it's alsocut-resistant.

In a nutshell, the main pros of Kevlar body armor are:

• Durable, yet lightweight
• Higher tensile strength than steel
• Highly resistant to cuts and abrasion

Cons

Kevlaronly protectsagainst low to medium velocity weapon rounds. Though it may be able to stop projectiles from lower-caliber rifles, these impacts will still result in significant blunt trauma.When considering steel vs. Kevlar body armor, for example, you'd probably prefer steel, UHMWPE, or ceramic if you need something more heavy-duty or expect to face high-caliber fire.

To minimize blunt trauma, ceramic, UHMWPE, or steel plates are often added toKevlar bulletproof vests. However, these plates compromise the sleekness and comfort of Kevlar, which are two of its biggest draws. Therefore, it can be impractical for civilians and police officers. As such, Kevlar combined with plate armor is more suitable fortactical forces indangerousenvironments.

Additionally, bullet-resistant though it is,Kevlaris easilydamaged by ultraviolet rays, dry cleaning,excessive washing and bleaching agents, so it takes some special care.

So, the cons associated with Kevlar are:

• Doesn't come in NIJ level III and IV options
• Added plates make the vest heavier
• Easily damaged by UV rays and cleaning agents

Find the Right Body Armor at Atomic Defense

The most ideal materialdepends on thethreat level you'refacing andthe amount of comfort you requirewhile wearing the body armor.If you needany assistancefinding the right protective gear for the job, Atomic Defense is here to help. Browse our selection ofbody armor platesorcontact us with questionsabout finding your ideal material.