Blog
24 Jun 2025
How to select the right body armour
Several key factors should be taken into account when selecting the most suitable body armour. It is essential to assess the expected threats, as well as the wearer’s body type and organisational preferences regarding design features and comfort. Carefully considering these elements ensures that the chosen body armour effectively fulfils operational needs while providing an optimal fit and usability.
Body armour components and types
Ballistic protection elements are integral to the personal protective equipment of every police and military unit. These elements enable the user to defend against threats of various types and, typically, are applied in bullet-resistant vests and plate carriers. The ballistic elements are available in a range of sizes and can be either flat or curved to fit different body shapes and sizes. Typically, neither the cover nor the carrier is designed to provide ballistic protection; their primary purpose is to support and secure the panels to the wearer’s body comfortably.
There are two primary categories of body armour:
Soft ballistic: A soft ballistic panel is made from flexible, ballistic-resistant materials and is designed to reduce the risk of trauma by protecting against projectiles from firearms. It can be combined with stab and impact protection to provide additional shielding from knives, needles, splinters, blows, collisions and falls. Soft ballistic can be worn beneath uniforms or over clothing in an external carrier, such as a waistcoat, for ease of use and comfort.
Hard ballistic: A hard ballistic plate is made from ballistic-resistant materials such as polyethylene and ceramics. It offers enhanced protection against lethal projectiles, including rifle rounds. It is typically used in tactical environments where hard ballistic plates are integrated into systems combining soft and hard armour, resulting in a thicker, heavier setup. This type of armour is generally not intended for prolonged wear, but rather for use when entering high-risk situations.
Ballistic protection elements are usually presented as one of two types of solutions: standalone (SA) or “in conjunction with” (ICW).
An SA solution is one in which only a single component is used. The one-component nature of the solution theoretically makes it easier to handle. An ICW solution, on the other hand, is understood to be a soft or hard ballistic paired with at least one other component. For example, you could have a soft ballistic panel, a trauma-reducing element, and a hard ballistic plate together. It is important that both types of ballistic protection elements be worn together in order to provide full protection.
Selecting the appropriate level of protection
The choice of body armour depends primarily on the specific threats faced by the operator. While no armour can offer complete protection against all dangers, it is important to recognise that it is impossible to achieve 100% safety in every situation. When selecting body armour, a balance must be struck between ballistic protection, comfort and wearability. Typically, the greater the level of protection, the heavier and bulkier the armour tends to be, which can impact comfort. Therefore, it is essential to choose body armour that operators are willing and able to wear consistently while still providing the necessary level of ballistic protection. Furthermore, operators must be fully informed about the capabilities and limitations of their body armour to ensure proper use and maximise safety.
Operational consideration
Law enforcement personnel:
The type and level of threat that law enforcement personnel may face depends largely on the operational scenario. For everyday use, agencies equipping their officers with soft body armour that provides protection against handguns. The appropriate level, such as NIJ Level IIA, II or IIIA or VPAM 1-3, should be selected based on the excpected threat environment.
For higher-threat scenarios, hard ballistic armour, typically classified as NIJ Level III or IV or VPAM 6 or 9, provides enhanced protection against rifle rounds and other ballistic threats. However, it is important to bear in mind that hard ballistic is generally less concealable, which may limit its suitability for operations where discretion is important.
Correctional officers:
Within the secure perimeter, the primary threat comes from improvised edged and stabbing weapons. In such cases, stab resistance is prioritised over ballistic protection.
Military personnel:
In military operations, armour requirements are shaped by the specific environment of the conflict and the range of threats, including small arms fire, shrapnel and explosive devices. Soldiers often require more comprehensive ballistic protection, such as high-level hard armour plates (Level III or IV) or VPAM 6 and 9, capable of stopping rifle rounds and fragmentation.
Military armour systems are usually designed to be modular, featuring options such as external pouches and attachments to enhance tactical flexibility. Built to be durable in challenging environments, they often incorporate advanced materials to reduce weight without compromising on protection. In combat zones, concealability is generally less important, so heavier, less concealable armour is a practical and necessary choice for maximum safety.
Dual-Purpose:
One option to consider is combined ballistic and stab-resistant armour. To qualify as dual-purpose, such armour must meet NIJ Standard 0101.06 for ballistic protection and NIJ Standard 0115.00 for stab resistance, or VPAM 3 for ballistic protection and VPAM test standard KDIW for stab resistance. While this dual protection offers versatility, it is usually heavier and bulkier than single-purpose soft armour designed solely for ballistic or stab protection. This can impact comfort and mobility.
Gender and body shape
When choosing body armour, it is important to consider the wearer’s body type, regardless of gender. There are two main models: Male and female, each of which is available in a variety of sizes to ensure a proper fit. In terms of design, there are no significant visual differences between male and gender-neutral armour as hard body armour is typically designed to be gender-neutral.
However, female soft body armour often features curved ballistic panels that are tailored to better conform to the female bust, enhancing both comfort and fit.
Design features
Operators and agencies may have specific preferences regarding various design features of body armor, including:
- Weight: Heavier armor can lead to increased fatigue during a mission, so weight considerations are vital for comfort and endurance.
- Covert versus Overt Vest: Armor can be worn discreetly under clothing (covert) or visibly over the uniform (overt). The choice typically depends on agency policies and operational needs.
- Customisable features: MOLLE, hook-and-loop, and laser-cut systems are essential for carrying equipment such as handcuffs, radios, and magazines.
Summary
Selecting the most suitable body armour requires careful consideration of the anticipated threats, the operator’s body type and organisational preferences. Body armour consists of various components, including soft ballistic panels and hard ballistic plates, which are designed to strike a balance between protection, comfort and mobility. Soft body armour provides flexible protection primarily against handgun threats, while hard body armour offers greater defence against rifle rounds, which are often used in tactical scenarios. Taking gender and body shape into account to ensure a proper fit is crucial for maintaining safety and comfort. Factors such as weight, thickness and fastener type should be tailored to operational needs. Ultimately, the right body armour for an individual depends on the specific threat environment, enabling officers to stay protected while preserving their mobility and endurance.
Images and graphics: Mehler Protection (all rights reserved, 2025)
