Since the dawn of time, humans have been searching for ways to protect our fragile bodies. As weapons evolved from simple stones to powerful firearms, those who develop armor technology have raced to keep up. Fortunately, modern science offers highly effective body armor solutions to keep us alive when faced with modern threats.
Whether for work, hunting, or home defense, body armor can help keep you safe. However, it’s essential to understand both the strengths and the limitations of these systems before you buy. As cool as it seems, a full-body Kevlar samurai suit probably isn’t the most practical investment. In this guide, we’ll explain the basics of body armor, some tips to consider when shopping, and our recommendations for the best bulletproof vests on the market.
What Is Body Armor?
Body armor is a wearable system designed to reduce the penetration of bullets, explosive fragments, and other projectiles. Its fundamental principle is to put a strong material between danger and your vital organs while retaining as much mobility as possible.
Modern body armor can include ultra-strong ballistic fabric, hard plates, stab-resistant materials, or a combination of all three. Which system you need will depend on your specific circumstances and the threats you’ll face. There are no one-size-fits-all solutions, and you may need to try several products to find one that works best for you.
While modern armor is extremely effective, it still has limits. Hollywood has created a perception that body armor somehow makes you superhuman or bulletproof, but this is not the case. Think of body armor as more like a seatbelt than an invincibility shield — it doesn’t make you immune to all harm, but it can save your life.
Depending on the range and caliber of the weapon threatening you, armor is usually the difference between a funeral and a trip to the hospital with serious contusions. If you get shot in the chest while wearing a bulletproof vest, you’ll probably live to talk about it, but it will still feel like you got hit by a truck. The impact might knock you unconscious, break a few ribs, or even cause some pretty bad internal bleeding.
The key value of body armor is peace of mind when you could be a direct or indirect target of a credible threat. It’s also valuable protection when you’re doing something really, really stupid (which we don’t recommend, of course) — but just in case, let’s take a closer look at how body armor works.
How Does Body Armor Work?
Body armor works by absorbing a projectile’s concentrated energy and spreading it out over a wider area to reduce penetration. The higher and more concentrated the energy, the stronger the armor needs to be.
Modern ballistic vests (also called bulletproof vests) are made from multiple layers of ultra-strong fabric, such as Kevlar or other aramid fibers. When tightly woven and overlapped, these materials can effectively distribute a bullet’s impact across a wide area, reducing or preventing penetration — and saving lives.
In addition to ballistic fabrics, bulletproof vests can include steel or ceramic plates, which are much stronger and capable of stopping higher-energy rounds. The tradeoff is that these plates are heavy and reduce mobility.
Bulletproof vests can also include stab- and slash-resistant materials to reduce penetration from (comparatively) low-energy attacks, such as knives or stabbing weapons. While bullets are much faster than knives, knives are sharper and can more easily fit between fibers, meaning different materials are required to defend against these threats.
Types of Body Armor
A wide variety of body armor is available, each type designed to deter a specific threat or to be used under specific circumstances. Here are some of the main types of body armor you might encounter as you shop:
- Ballistic vest: This is a soft-fabric bulletproof vest generally designed to stop handgun rounds. While these vests are ineffective against large-caliber rifles and stabbing weapons, they are lightweight and comfortable, allowing for excellent mobility.
- Ballistic vest with plates: These vests are a mix of soft and hard armor, so they provide more protection against both small- and large-caliber rounds. Of course, the plates are heavier, which decreases comfort and limits mobility.
- Plate carrier: To maximize mobility, these systems avoid soft armor altogether and just provide a holder for front and back hard-armor plates. These are best for tactical or hunting scenarios where the main threat is high-caliber weapons.
- Stab-proof vests: These vests are specifically designed to deal with spiked and edged weapons but may not resist bullets. Stab-proof inserts can be added to other systems.
- Bullet-resistant clothing: If you want to be particularly discreet, ballistic hoodies, jackets, pants, and other garments are available. The idea is to provide some protection while maintaining a low profile.
- Bullet-resistant accessories: Armored accessories, such as backpacks and briefcases, are particularly useful in a mass-shooting scenario, which can happen just about anywhere (schools, malls, public streets, etc.). A bulletproof backpack or hoodie still serves a purpose while also providing protection against threats, increasing the likelihood you’ll actually wear it on a regular basis.
Body Armor Protection Levels
Body armor also varies in the threats it can defend against. The following are standardized protection levels as certified by the National Institute of Justice (NIJ), a division of the U.S. Department of Justice.
- Level IIA: This is the least effective but most concealable armor. If you need some protection against small-caliber rounds, IIA armor is better than nothing. These vests can protect against rounds up to .40 caliber.
- Level II: This armor provides a good balance of weight and protection against rounds up to .357 caliber.
- Level IIIA: As the most commonly recommended level of protection, these vests protect against nearly all handgun rounds, including .44 Magnum and most shotgun rounds.
- Level III: This armor level is designed for combat, providing protection against high-energy rifle calibers, such as 7.62.
- Level III+: This armor level is not technically an official rating. Manufacturers developed III+ armor to indicate additional protection against 5.56 rounds.
- Level IV: This is the highest protection level available, protecting wearers from armor-piercing rounds.
Bulletproof Vest Buying Considerations
Choosing a bulletproof vest is not as simple as just buying the “best” one. You’ll need the right armor for your specific circumstances and the most likely threat. While there’s no way to prepare for every situation, think about it this way: the armor requirements of a bodyguard, police officer, hunter, nightclub doorman, and home defender are all vastly different.
Generally, choosing armor is about measuring the tradeoffs between certain characteristics. Here are a few important factors to consider when buying body armor:
- Type of Threat: As the most important factor, you should consider whether you might be facing bullets, edged weapons, explosives, or a combination of these. You need to be sure your body armor covers at least what you are most likely to encounter.
- Protection Level: Review the official protection levels above and be sure whatever armor you choose is officially rated with a protection level that matches the threats you may realistically face. However, keep in mind that protection might limit mobility, which may decrease your ability to respond effectively in a violent encounter.
- Weight: The more protection you have, the heavier your armor will be, which can limit comfort and mobility. If you plan on wearing this armor during strenuous activity or exercise (even walking long distances), weight is a crucial consideration.
- Comfort: Will you be wearing the vest for 12-hour shifts or only putting it on for five minutes to confront a home intruder? In addition to weight, your armor’s design, materials, and adjustability also play a key role in comfort. If possible, try on some options before you buy.
- Mobility: While wearing a bulletproof vest, driving a vehicle or standing at a door will be easier than running, climbing, or fighting. The goal is not to be invincible but to survive. Sometimes, mobility is more important than any other factor — you don’t want to be bogged down by clunky, heavy armor when you need to leap into action.
- Concealability: For home defense or hunting, concealability isn’t important. If you’re wearing a bulletproof vest around the mall or standing at the door of a nightclub, it might be important to have one that isn’t so obvious. Also, if you’re wearing this on a regular basis, you want it to feel natural with your everyday outfits.
- Cost: Armor isn’t cheap, so it’s important to carefully assess your situation to be sure you need it. By spending more, you can sometimes achieve higher levels of protection at a lower weight, delivering better comfort and mobility without sacrificing security.
- Warranty: Buying a bulletproof vest is like buying a parachute: you won’t know it’s failed until it’s too late. However, good warranties will guarantee against manufacturing defects and issues with material quality or durability. If you notice a problem with your vest, you can easily get it replaced before it turns into a risk factor.
- Legality: Body armor is currently legal in all 50 states, but there are some limitations. For example, you can’t own armor if you’re a convicted felon, and for some reason, you can’t buy armor online in Connecticut. In New York, bulletproof vest owners must work in an approved profession. Check out your local laws to be sure you’re compliant.
Our Picks for the Best Bulletproof Vests
To help you choose the right options for you, here’s our list of the best bulletproof vests you can find at reasonable prices:
Best Plate Carrier: Armored Republic Testudo Gen 2
The Testudo Gen 2 is a fully adjustable plate carrier with side pouches for additional protection. This plate carrier is a good option for hunting or high-mobility tactical scenarios.
Basic Info
- Armor pocket: Supports 10x12” & 11x14” plates (sold separately)
- Material: 500D Nylon
- Color: Olive drab or black
- Size: M to 3XL
Key Features
- Pockets for side plates
- Kangaroo & admin pouches
- PALS webbing
- Adjustable cummerbund
- Comfortable padding
Best Armor Plate: Armored Republic A2 Level III+ Lightweight Steel Armor
Rated for 5.56x45 M193 and 5.56x45 M855/SS109 at 3,000 FPS, the A2 Level III+ steel plate is a smart pick for several scenarios. This lightweight armor is designed to fit the Testudo plate carrier, providing excellent protection against high-caliber rounds at just over five pounds.
Basic Info
- Ballistic protection: Level III+
- Material: Ballistic steel alloy
- Weight: 5.5 lbs
- Thickness: 0.26”
- Shelflife: 20 years
- Size: 10” x 12” (fits Testudo plate carrier)
Key Features
- Edge-to-edge multi-hit protection
- Low profile, low weight
- Super durable FragLock coating
- Curved, shooter’s cut design
- Can absorb several hits without shattering
Best Concealed Vest: SafeGuard CoolMAX Covert Vest
The SafeGuard CoolMAX Covert vest is designed to be worn under clothes, delivering a good mix of ballistic and stab protection. This vest is great for security personnel or bodyguards who need to maintain a low profile.
Basic Info
- Ballistic protection: Level II
- Stab protection: Up to 24 joules
- Materials: Aramid, poly-cotton
- Color: Black
- Size: S to 4XL
Key Features
- Good mix of ballistic and stab protection
- Adjustable straps for a perfect fit
- Comfortable for long wear
- Excellent concealability
- Ventilated CoolMAX mesh lining
Best Maximum Protection: Safe Life Defense Tactical Enhanced Multi-Threat Vest
The Tactical Enhanced Multi-Threat Vest from Safe Life Defense is the ultimate armor solution, providing maximum protection for the worst situations. This is a great choice for home defense or overt security work in dangerous areas.
Basic Info
- Ballistic protection: Level IIIA+
- Stab protection: Up to 36 joules
- Materials: Para-aramid
- Colors: Black, tan, green, blue
- Size: 4XS to 7XL
Key Features
- Bullet, strike, and slash protection
- Expanded pockets for optional Level IV protection
- Front and back MOLLE webbing
- Rear drag/rescue handle
- Six-point adjustable straps
- Cooling mesh liner
Best Armored Backpack: Armored Republic Phoenix
The Phoenix provides discreet protection for everyday use — and it still functions as a high-quality backpack. Whether for yourself or your loved ones, this armor might be the deciding factor in a worst-case scenario.
Basic Info
- Ballistic protection: IIIA
- Materials: DuPont Kevlar, Honeywell Spectra Shield, 1680D Cordura Hypalon
- Weight: 3 lbs
- Shelflife: Five years
- Colors: Black, blue, gray, mauve
Key Features
- Stops bullets used in 95% of gun-related homicides
- Completely discreet
- Fully functional backpack
- Padded for comfort
- Sewn-in armor
- Laptop sleeve doubles as optional armor upgrade pocket
Conclusion
Now that you have a better idea of how body armor works, you’ll know what to look for if you are thinking of buying your own bulletproof vest or other piece of body armor. Bulletproof vests aren’t cheap, so remember to carefully consider your situation and potential threats before buying. Above all, don’t compromise on quality — your life could actually depend on it.
If you’re in the market for high-quality protection, check out our body armor options at Pro Armory. We’re veteran-operated, so we know how important it is to be well-equipped. That’s why we offer a wide variety of hard and soft armor, as well as other tactical accessories, to make sure you’re prepared for any situation. Build your ultimate tactical loadout today with guaranteed secure purchases online at Pro Armory.