What body armor does the military use

The U.S. military relies on advanced body armor systems such as the Improved Outer Tactical Vest (IOTV), Modular Scalable Vest (MSV), and Enhanced Small Arms Protective Inserts (SAPI/E-SAPI plates) for protection. Different branches and units select specific configurations to match operational demands. Kevlar remains a primary material in both soft and hard armor components, providing essential protection against ballistic threats.

The Interceptor Body Armor (IBA) system served as a foundation for modern military body armor. The Army shifted from the Outer Tactical Vest to IOTV and then to MSV, while the Marine Corps adopted the Modular Tactical Vest and Scalable Plate Carrier. The Navy and Air Force tailor their body armor choices based on mission requirements, often leveraging Marine Corps and Army research for updated solutions.

Kevlar, ceramics, and composite materials enhance bulletproof vests and interceptor body armor, ensuring that military personnel receive the best possible protection.

Key Takeaways

• The U.S. military uses advanced body armor systems like the Improved Outer Tactical Vest and Modular Scalable Vest to protect soldiers in different missions.
• Kevlar is the main material in soft armor, offering lightweight and flexible protection against shrapnel and low-velocity threats.
• Hard armor plates made from ceramics and composites stop high-velocity bullets but must balance protection with weight to maintain soldier mobility.
• Each military branch chooses body armor tailored to its needs, with special forces using lighter, more adaptable gear for their unique missions.
• Civilians can legally buy most body armor in the U.S., but laws vary by state, so checking local rules before purchasing is important.

Types of Military Body Armor

Modern military body armor systems combine advanced materials and modular designs to maximize protection and mobility. The U.S. military equips personnel with a range of armor types, each tailored to specific operational needs. These systems have evolved from earlier models like the interceptor body armor to current solutions such as the improved outer tactical vest and modular scalable vest.

Soft Armor

Soft armor forms the foundation of most military body armor systems. Manufacturers use layers of kevlar and other ballistic fibers to create flexible panels that protect against shrapnel and low-velocity projectiles. Soldiers often wear soft armor as part of the outer tactical vest or as concealable vests under uniforms. Kevlar remains the primary material due to its high tensile strength and lightweight properties. The improved outer tactical vest incorporates multiple layers of kevlar, providing essential ballistic protection while maintaining comfort and flexibility.

Soft armor panels excel at stopping fragmentation threats, which account for a significant portion of battlefield injuries. The modular scalable vest and other modern vests use advanced kevlar blends to enhance protection without adding unnecessary weight. Ergonomic studies show that lighter ballistic vests improve soldier mobility and reduce fatigue. For example, research by Majchrzycka et al. (2013) found that lighter plates, weighing between 2.10 and 3.18 kg, received the highest ergonomic ratings among military males.

Hard Armor

Hard armor provides critical protection against high-velocity rifle rounds and armor-piercing threats. The military integrates hard armor plates, such as enhanced small arms protective inserts, into vests like the improved outer tactical vest and modular scalable vest. These plates use advanced ceramics, steel, or composite materials layered over kevlar backings. Enhanced small arms protective inserts offer a significant upgrade over earlier SAPI plates, delivering improved ballistic protection against modern threats.

Testing protocols for hard armor follow strict military standards, including Army MIL-STD-662F and STANAG 2920. These standards require plates to withstand specific ballistic and fragmentation threats. The Army, Navy, Air Force, and Marine Corps now use unified testing protocols developed by the Office of the Director, Operational Test and Evaluation. This approach ensures consistent performance and safety across all branches, even as each service adapts armor configurations to mission requirements.

The weight of hard armor remains a key consideration. Studies consistently show that heavier body armor impairs mobility, balance, and marksmanship. The following table summarizes findings from recent research on body armor weight and its impact on performance:

These findings highlight the importance of balancing ballistic protection with operational effectiveness. The military continues to refine hard armor systems, seeking lighter and stronger materials to reduce the burden on personnel.

Plate Carriers and Vests

Plate carriers and vests serve as the backbone of modern military body armor. The interceptor body armor system marked a significant advancement by integrating soft kevlar panels with removable hard plates. The outer tactical vest, a key component of the interceptor body armor, provided modularity and improved fit. Over time, the improved outer tactical vest and modular scalable vest replaced earlier models, offering enhanced protection and adaptability.

Current plate carriers, such as those used by special operations forces, prioritize weight reduction and comfort. Manufacturers use advanced kevlar blends and ultra-high-molecular-weight polyethylene (UHMWPE) fibers to create lighter, more flexible ballistic vests. The following table outlines performance improvements observed in newer plate carriers and vests compared to older models:

These advancements translate into lighter, thinner, and more comfortable armor with superior ballistic protection. The military now fields full armor systems like the FAS™, which integrate kevlar, ceramics, and advanced composites for maximum survivability. Enhanced small arms protective inserts and modular scalable vests represent the latest evolution in military body armor, reflecting a continuous drive for better protection and performance.

▶Note: The evolution from interceptor body armor to current systems demonstrates the military’s commitment to improving both survivability and operational capability. Kevlar remains central to these innovations, ensuring that soldiers receive reliable ballistic protection in diverse environments.

By Branch

Army and Marines

The Army and Marine Corps issue different body armor systems to meet their unique operational needs. The Army relies on the Interceptor Body Armor (IBA) and Enhanced Small Arms Protective Inserts (E-SAPI), with ongoing tests of advanced plates like XSAPI for higher ballistic protection. The XSAPI plates use additional materials to defend against armor-piercing rounds and fragmentation, reflecting the Army’s focus on increased survivability. The Army also develops the Torso and Extremity Protection (TEP) system, which includes scalable components such as a ballistic combat shirt and pelvic protection. This system aims to improve mobility and operational flexibility.

The Marine Corps has transitioned through several body armor systems, including the Modular Tactical Vest (MTV), Scalable Plate Carrier (SPC), Improved Modular Tactical Vest (IMTV), and now the Improved Scalable Plate Carrier (ISPC). The ISPC offers high customization, especially for Marine Raiders. Both branches use the IBA system, but the Marines prioritize next-generation plate carriers tailored for their missions. According to a 2016 Government Accountability Office report, Marines carried an average combat load of 117 pounds, while Army troops carried 119 pounds, with body armor contributing significantly to this weight. These differences highlight distinct modernization strategies and operational requirements.

Air Force and Navy

The Air Force and Navy adapt their body armor systems based on mission profiles and evolving threats. The Air Force uses the Torso Extremity Protection Program (TEP), a modular and scalable system that allows commanders to adjust protection levels. This system improves fit and mobility for Airmen, addressing threats from fragmenting munitions, handguns, and small arms when combined with hard armor inserts.

Recent conflicts have shifted injury patterns, with blast and fragmentation injuries now more common than gunshot wounds. The following chart illustrates the change in injury types across major conflicts:

This data shows that modular armor systems focusing on extremity and torso protection are essential for both branches. The Navy often leverages research from the Army and Marines, ensuring that sailors and naval security forces receive up-to-date military body armor solutions.

Special Forces

Special Forces units require body armor tailored to their unique missions. Operators provide direct feedback to manufacturers, influencing the design for comfort, modularity, and protection. This collaboration leads to specialized systems like the Eagle MBAV and Crye AVS, which offer high adaptability and reduced weight. Advanced projects, such as the ExoM exoskeleton, demonstrate the focus on mission-specific needs.

Special Forces also face rigorous evaluation processes for new equipment. For example, the controversy over Dragon Skin body armor and the adoption of the Heckler & Koch 416 carbine by Army Special Forces highlight the distinct requirements and rapid adaptation seen in these units. These teams often select body armor based on mission demands, balancing protection, mobility, and comfort.

Body Armor Materials

Kevlar and Ballistic Fibers

Kevlar stands as the backbone of modern body armor. The military relies on kevlar for its high strength-to-weight ratio and outstanding impact resistance. Manufacturers weave kevlar fibers into flexible panels, which absorb and disperse energy from projectiles. This material forms the core of soft body armor and often serves as a backing for hard plates. Research highlights kevlar’s dominance in defense applications, with studies showing that its composites offer excellent ballistic protection and durability. Treatments such as shear thickening fluids further improve kevlar’s resistance to high-velocity impacts.

Kevlar remains the benchmark for ballistic fibers, but ongoing research explores alternatives. For example, piassava fiber/epoxy composites and coconut sheath hybrids have shown comparable or superior performance in some tests. The table below summarizes key findings from recent research:

Kevlar’s flexibility and light weight help reduce fatigue and improve mobility for military personnel. These features make kevlar a preferred choice for body armor in demanding environments.

Ceramics and Steel

Ceramic plates play a critical role in hard body armor. The military uses ceramics such as silicon carbide and boron carbide to stop armor-piercing rounds. Ceramics shatter incoming projectiles, dispersing energy and reducing blunt trauma. Compared to steel, ceramic plates weigh less and offer superior ballistic protection against modern threats. The table below compares ceramic and steel plates:

Steel plates offer durability and multi-hit capability but add significant weight to body armor. They also increase the risk of spall, where fragments can injure the wearer. Ceramics, while lighter, require careful handling and have a shorter service life. The military balances these factors to ensure optimal ballistic protection and comfort.

Advanced Composites

Advanced composites represent the latest innovation in body armor. The military incorporates materials such as ultra-high molecular weight polyethylene (UHMWPE), carbon fiber, and phenolic-coated fiberglass to enhance performance. These composites provide significant weight savings and improve energy absorption. For example:

• Phenolic-coated fiberglass offers fire resistance and low flammability.
• Carbon fiber composites increase structural strength while reducing weight.
• UHMWPE fibers deliver flexibility and high ballistic protection.

Recent advances focus on layering high-performance fibers and composites to maximize protection and comfort. Composite backplates reinforced with carbon nanotubes have shown improved ballistic resistance in tests. However, these materials require specialized manufacturing and careful design to balance weight, flexibility, and durability. The military continues to refine composite body armor to meet evolving threats and operational needs.

Civilian Access

Legal Issues

Civilians in the United States can legally purchase and own body armor in most states. Federal law allows individuals over 18 years old, who do not have violent felony convictions, to buy and wear body armor. However, some states have introduced or considered stricter regulations. New York stands as the only state with a complete ban on civilian body armor. Other states, such as California, Illinois, and Connecticut, have proposed bills to limit or criminalize possession, but these measures often face strong opposition.

The following table summarizes current legal restrictions and public opinion:

Most Americans believe that access to body armor supports personal safety and constitutional rights. Law enforcement and some civilians argue for restrictions, citing concerns about criminals gaining an advantage. Veterans and many civilians emphasize the importance of self-defense.

▶Note: Laws can change quickly. Individuals should always check local regulations before purchasing or wearing body armor.

Availability

Body armor designed for military use is widely available to civilians through online retailers and specialty stores. Most companies sell soft armor, hard plates, and plate carriers that meet or exceed National Institute of Justice (NIJ) standards. However, some advanced military body armor systems, such as those with classified materials or technologies, remain restricted to government agencies.

Civilians often choose body armor for personal protection, security work, or recreational activities like airsoft and paintball. While many products match the protection levels of military gear, practical differences exist. Military body armor may offer enhanced durability, modularity, and resistance to extreme conditions. Civilian models focus on comfort, concealability, and cost-effectiveness.

Buyers should consider the intended use, legal requirements, and product certifications. Reputable sellers provide clear information about protection levels and compliance with federal and state laws. Responsible ownership ensures that body armor serves its intended purpose—protecting lives.

Military branches select body armor systems like the IOTV, MSV, and specialized plate carriers to match their operational needs. Material innovations, such as Kevlar, ceramics, and smart textiles, have improved both protection and comfort. Over time, ergonomic designs and modular features have enhanced mobility for service members. Those seeking more information or civilian options should review product certifications and local laws. For the latest updates, always consult official military or government sources.