Jonas Olesen October 30, 2024 10 min read

14 things you didn’t know about a bulletproof vest

 

A bulletproof vest is more complex than it seems. To provide insight, we’ve created a brief article titled “14 Things You Didn’t Know About a Bulletproof Vest.”

1. In principle, a bulletproof vest is not entirely bulletproof

A bulletproof vest is not entirely “bulletproof,” but rather bullet-resistant. It does not guarantee 100% protection against all types of bullets, and impacts can still cause blunt force trauma and backface deformation, which can be lethal. No vest is completely impervious to bullets or stabs.

For instance, an NIJ Level 3A vest is designed to stop most small arms bullets. However, in extreme cases, it may still be penetrated, especially by armor-piercing (AP) rounds like 9mm AP, which are specifically designed to breach soft armor materials. Wearing a bulletproof vest doesn’t make you invincible; it’s crucial to understand its limitations.

2. How does a bulletproof vest stop a bullet?

Bulletproof vests are constructed from multiple layers of bullet-resistant fibers. (You can find more details about these materials here.) The vest functions somewhat like a soccer net—when a ball hits the net, the energy is dispersed across the entire structure.

The bullet’s velocity also plays a crucial role. Lower-speed bullets cause less blunt trauma to the wearer, while high-velocity bullets can more easily penetrate the vest. For example, high-speed rounds like the 7.62×51 NATO or SS109 can penetrate soft body armor without the additional protection of hard armor plates

3. Every bullet is lethal

As previously mentioned, every bullet has the potential to be lethal, and no bulletproof vest can guarantee 100% effectiveness in stopping a bullet every time. The force from a shot, known as blunt force trauma, can still cause significant injury, potentially rendering the wearer unconscious or even causing death.

According to NIJ Standard 0101.06, bulletproof vests must maintain a backface signature below 44 mm to help ensure the wearer’s survival by minimizing the depth of the impact.

4. Lifespan of a bulletproof vest

Most bulletproof vests have a lifespan of 5 years, as specified by National Institute of Justice (NIJ) standards, which require vests to maintain effectiveness for at least this duration. However, frequent use—whether daily or on weekends—can reduce the vest’s durability more quickly than minimal use.

It’s essential to regularly inspect the panels for signs of wear, such as scratches or moisture exposure, and to ensure that the panel’s sealing remains intact. With proper care and maintenance, a vest should remain reliable throughout its 5-year lifespan.

5. Keep your bulletproof vest away from moisture

After a long day / night it is always recommended that you take your bullet proof inserts out of the bulletproof vest. This is partly to take care of the bulletproof inserts, but also to check if the bulletproof inserts have taken any damage and to avoid moisture. Whether your ballistic vest is made in Kevlar, Dyneema, Twaron or any other ballistic material, there is no need to expose the bulletproof vest to moisture.

Remember that the carrier and ballistic inserts should be washed separately, and NEVER wash the bulletproof inserts in a wash machine. Do not iron the inserts as well, as it will burn / melt the bulletproof fibers inside the vest. To properly maintain and care for the inserts, gently clean them with a damp cloth. Avoid using harsh chemicals or submerging them in water to preserve their integrity and effectiveness.

6. Store your vest in a closet or a flat, dry place

The inserts in a bulletproof vest should never be stretched or bent for prolonged periods, as this can cause the fibers to separate, reducing their durability and compromising their protective capabilities.

Store your vest in a flat, shaded area, such as a closet, to avoid direct sunlight exposure. When returning home from work, refrain from leaving your sweaty vest on the floor or in a corner. Sweat can penetrate the fibers and weaken the material over time, diminishing its effectiveness.

7. Never expose your bulletproof vest to water for testing purposes

Just like moisture and sweat, water can severely damage a bulletproof vest and eventually compromise its effectiveness.

Under NIJ Standard 0101.06, vests must undergo a 30-minute water immersion before testing. While most manufacturers use waterproof materials to protect the vest, it is essential for your safety not to expose it to water intentionally or attempt to test its waterproofing yourself.

8. If you’re shot. Don’t give up!

In many movies, you often see the hero get shot and then miraculously wake up moments later thanks to a bulletproof vest. In reality, the impact of a bullet feels more like being struck by a powerful paintball gun, but with three times the force. This results in significant bruising and considerable pain.

Today, many manufacturers have improved the design of bulletproof vests to minimize blunt force trauma, reducing the impact and pain experienced by the wearer.

9. Have multiple carriers if the bulletproof vest is used a lot

If you work as a guard, bouncer, or police officer, and wear your vest daily, it is advisable to have multiple carriers to rotate between. This helps manage moisture buildup and maintain the carrier’s durability. Over time, as a vest loses its structural integrity, its fit deteriorates, which can result in poor coverage in high-movement situations, leaving critical areas unprotected.

10. If you lose or gain weight, you need a new bulletproof vest

A simple rule to follow is to maintain your weight within ±10% of your initial weight. Significant changes can affect the fit of your vest, compromising its effectiveness and comfort. A bulletproof vest should fit snugly to the body, without being too tight or too loose. Read more information on selecting the right size.

11. Your carrier does not protect you without the bulletproof panels!

This point is straightforward: the carrier alone will not provide protection without the bulletproof panels inside, nor will it protect against sweat. For more information, refer to point 5.

12. If you are in a traffic accident your bulletproof vest can save you

The fibers in a bulletproof vest can withstand more than just bullets. In certain situations, such as traffic accidents, the vest can be a lifesaver. There have been cases where American officers were protected by their vests during collisions, highlighting their additional benefits beyond ballistic protection.

13. Duct tape should never be used to replace a damaged carrier

Never attempt to repair a damaged bulletproof vest with duct tape or modify its fit. Here are two key reasons: duct tape restricts flexibility, reducing your ability to move effectively in critical situations, and it compromises the vest’s integrity.
If your vest is damaged, replace the carrier instead. Replacement carriers are typically available at a reasonable cost and will ensure your safety and mobility are not compromised.

14. Never let your bullet- and stab-proof vest lie at home

Once you’ve purchased a bulletproof vest, there’s no point in leaving it unused at home. Wear it consistently—you never know what situations you might encounter where it could be vital to your safety.

Read more about bulletproof vests and soft armor inserts.