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Lightweight, ergonomic, non-ceramic ballistic armor offers more comfort and mobility for deployed warfighters. (Photo illustration by Armacel Armor Company)
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New Body Armor is Lighter, Cooler, Safer
Posted 6/23/2011 Updated 6/23/2011
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by Lt. David Fortson
Materials and Manufacturing
6/23/2011 - WRIGHT-PATTERSON AIR FORCE BASE, Ohio -- Air Force personnel are losing weight and gaining comfort thanks to new non-ceramic ballistic armor developed by the Air Force Research Laboratory. Working with Universal Technology Corporation and Armacel Armor Company, AFRL scientists developed armor that demonstrates protection against ammunition from shoulder-fired weapon threats while weighing 32 percent less than current armor systems.
The new body armor technology also increases the survivability of warfighters in armed conflicts, while its lighter weight translates into increased mobility and a decrease in thermal load. Based on stopping power and back face deformation against standard small arms fire, the new armor offers significantly improved ballistic performance and ergonomic benefits.
The current standard for body armor, known as Enhanced Small Arms Protective Inserts (ESAPIs), combines a ceramic and composite material torso plate with a woven aramid multi-ply carrier system. While the ESAPI system is effective against rifle threats, the material is fragile, the ceramic strike face is breakable, can fracture with rough handling, and the carrier system is obtrusive and heavy.
The new ballistic armor technology uses polymer and composite materials technologies; advanced manufacturing processes are also being developed to provide the warfighter with affordable, survivable body armor. One advantage of the new system is that it can be molded into more complex shapes, offering designers more options.
The armor was tested during a Tech Warrior Pre-Deployment exercise in a simulated operational environment. It is currently deployed to military personnel at Bagram Air Base, Afghanistan, where scientists are conducting non-combat ergonomic fit testing and eliciting feedback from deployed Air Force personnel.
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