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BODY ARMOR UPDATE: 2004
By Christa
M. Miller
Headlining this
year’s body armor news is a new development in Second Chance Body Armor Inc.’s
continuing legal battles. The company had been under fire for several ballistic
vest failures: A number of their vests used the strong and lightweight, but also
inconsistently performing, Zylon® fiber.
In April, the Minnesota Attorney General’s office filed a lawsuit against Second
Chance. This suit is based on documents alleging that the company not only knew
of Zylon’s degradation problem, but also chose not to correct it.
The problem
began in 2001 when Toyobo Co., Ltd., manufacturer of Zylon, made available data
which showed that the fiber degraded much faster and more severely than did
other fibers in hot and humid conditions. In June 2003, two officers were
injured and one was killed because bullets penetrated their Second Chance Zylon-based
vests. The company removed their Zylon Ultima and Ultimax vests from the market
in September 2003, and ensuing lawsuits brought by both individuals and state
attorneys general seek both tort damages and restitution for vest buyers.
The Body Armor
Shortage
A second
worrisome issue to law enforcement is a shortage of body armor. Georg Olsen,
General Manager at U.S. Armor Corporation, says there are two reasons for the
shortage: increased demand from military troops and civilian contractors in
Iraq, and the Zylon controversy. “Police departments across the country are
scrambling to replace orders of Zylon-based vests because of known problems with
certain Zylon models and suspected problems with others,” says Olsen.
However,
they’re finding it no easy task to replace the vests: The troops are the
priority. When the war in Iraq started, only dismounted combat soldiers received
ballistic armor with ceramic Small Arms Protective Insert (SAPI) plates.
However, attacks on convoys carrying noncombat troops led to Congressional
debates as to why all troops did not have the same protection. According to a
2003 Washington Post report, “Three manufacturers are working overtime to
produce the 80,000 vests and 160,000 plates required to outfit everyone in Iraq
by the end of the year. Assembly lines are producing 25,000 sets a month.”
“The military
has put the DX designation on ballistic material, meaning it has to be used
first for them and then for the commercial markets,” Olsen explains. “In
particular, their demand is for Honeywell’s SpectraShield®,
which every manufacturer uses for hybrid blends. The Defense Department
estimates that about 92% of SpectraShield is currently going into military
production of antirifle plates and armored Humvees.”
In addition to
military demand, says Olsen, “U.S. Armor is doing significant business with
civilian contractors rebuilding schools, homes, and oil fields in Iraq.” As of
two weeks ago, the Coalition Provisional Authority (CPA) estimated that there
were 2500 “active open” contracts in the country, each of which requires a
minimum of 100 security personnel. “Do the math and you quickly realize there is
a second army in Iraq,” Olsen says.
In the short
term, he expects shipping delays because of increased demand from both military
and law enforcement markets. “The armor companies are aware of the physical and
emotional issues involved with the shortage, but we can only produce so much
material,” he says. U.S. Armor, for example, is expanding its production to keep
up with demand and even military body armor producers are feeling the squeeze.
“They can only use so much material at a time,” he says. “So, our hope is that
eventually the materials distribution will even out.”
Although Olsen
can’t provide a time frame for when the shortage will be mitigated, he says,
over the long term, the demand from both military and law enforcement markets
will eventually slow. “Zylon vests will be replaced and the contractors and
troops will get the protection they need,” he says. “This is a difficult time,
but, historically, we’ve seen this before and we’ve been able to cope.”
In the
meantime, along with diminished supply, Olsen says to expect fewer new products
as well. “This really isn’t the climate in which to introduce new material,” he
says. Not only are manufacturers reluctant to repeat mistakes similar to the
ones made with Zylon, but the market also hasn’t left much room for development.
“A normal market is a great time to introduce new product lines, but, right now,
we’re just involved with using buckets to bail ourselves out of the flood of
demand,” Olsen explains. “We haven’t been able to find a plug for the hole.”
However, even
with research and development of new body armor products being relegated to the
back burner, here are some new offerings for 2004:
American Body
Armor
American Body
Armor’s latest offerings are the IMPULSE™ i20
and the IMPULSE i50. By incorporating two distinct ballistic configurations
derived from long proven industry materials, the Impulse lineup satisfies the
needs of agencies whose wear specifications and budget are limited more to
meeting basic needs and having an affordable option.
DSM Dyneema LLC
The Dutch
inventor and manufacturer of a polyethylene material called Dyneema®,
DSM has opened a Greenville, North Carolina-based production line for
bullet-resistant fiber and material. The new plant, its first yarn production
line in the U.S., will produce materials exclusively for the U.S. military at
first, due to higher demands.
reviously,
DSM’s U.S. production lines put out unidirectional bullet-resistant material for
aircraft cockpit doors only. However, the company views the U.S. as its “second
home market” and is exploring investment options to capitalize on growing North
American demand.
Dyneema is
billed as “the world’s strongest fiber,” 15 times stronger than steel and 40%
stronger, weight for weight, than aramid fibers, KEVLAR® and
Twaron®,
its competitors. It floats on water and resists abrasion, moisture, ultraviolet
rays, and chemicals. In addition to bullet-resistant materials, Dyneema is used
for metalworking safety gloves and ropes; cabling and nets for fishing;
shipping; and offshore industries.
DuPont, Inc.
DuPont’s new
patented KEVLAR Comfort XLT is touted as providing more comfortable body armor,
weighing at least 25% less than conventional all aramid systems. Pacific Safety
Products and Armor Holdings Products Division have used the new technology and
the vests were displayed at the 100th Annual IACP Conference.
ForceOne, LLC
ForceOne,
previously a manufacturer of only soft body armor, has opened a hard armor
division. The decision has allowed it to become one of the military’s major SAPI
(Small Arms Protective Insert) manufacturers. Additionally, ForceOne offers
lightweight Level III plates, steel plates and Level IV plates and, in
cooperation with Salazar Law Enforcement Group, has added a line of helmets,
gloves and holsters.
ForceOne
continues to offer a full line of concealable, tactical, and K-9 ballistic
vests. Future redesigned vest features will include a front opening tactical
vest, a ballistic stab vest, and new ballistic packages combining better comfort
and protection. Part of ForceOne’s pursuit of better comfort is a new T-shirt
made with moisture wicking technology which helps officers stay cooler under
their vests.
Gator Hawk
Armor, Inc.
This
manufacturer recently introduced its Second Generation Gator Lite Series.
According to
David M. Daggett, Chairman and CEO of Gator Hawk, the Gator Lite Series,
introduced in 2001, has been their most successful. The Second Generation Gator
Lite weighs less per square foot, yet maintains exceptional performance.
For a limited
time, all Gator Lite orders will receive the Second Generation Lite ballistic
package at no additional cost.
Instant Armor,
Inc.
Instant Armor,
Inc. has added a feature to its 1st Responder Tactical Blanket System™.
The housing for the Tactical Blanket and its accessories, Softcase, can now be
used as an emergency stretcher. A second set of aluminum extension poles can be
inserted into the Softcase’s eight pole straps (four per side), allowing the
stretcher to be carried by two or four individuals. The modification is now
standard on all 1st Responder Softcases and costs nothing extra.
K9 Storm, Inc.
New to K9
Storm’s tactical product line is its K9 Storm Aerial Insertion Vest. Designed
for dogs being lifted or lowered into their work zones, the Level IIIA rated
vest has a built-in load bearing harness system rated to 2500 pounds. With an
outer carrier made of 1000 denier desert camouflage Cordura® and
an expandable Lycra™ panel,
the Aerial Insertion Vest provides ballistic protection using an aramid-based
Spectra® Gold
Flex® belly
panel.
The United
States Coast Guard uses the single V-ring Aerial Insertion Storm during helo
hoist deployments on their ships at sea, while the double V-ring Aerial
Insertion Storm is made for dogs deployed on parachute missions.
Pinnacle Armor
Pinnacle
Armor’s SOV flexible rifle defeating military body armor is now 26% lighter. A
flexible, lightweight, multiple hit capable armor system, it’s designed to
replace current rigid plate systems. SOV body armor, at only .858" thick, is
thin enough to be worn concealed. The armor is designed for load bearing “Alice
webbing,” “MOLLE webbing,” VELCRO®/snap,
or permanent attachment arrangements. Coverage areas per standard sizing are
larger than in other vests: One square foot of protected area withstood 18 .308
caliber rounds of M80 NATO ball ammunition from 15 feet at roughly 2900 feet per
second. The U.S. Army Research Laboratory, Weapons & Materials Research
Directorate (ARL) in Aberdeen, Maryland, will be testing the improved
lightweight armor for the military.
A second
Pinnacle achievement is a new patent for its body armor which defeats armor
piercing handgun and high energy fragmentation. The system is designed for
concealed or tactical use and the areas of coverage are variable up to, and
including, the entire vest.
PROTECH Armored
Products
PROTECH Armored
Products introduces exo, a new ballistic package for tactical body armor.
Designed to absorb energy across the vest’s surface instead of toward the center
of impact, exo is a framing structure, comparable to an exoskeleton, attached to
the vest’s ballistic panels. It redistributes energy from the bullet into the
frame and, in doing so, lessens the bullet’s impact. Because of its exterior
placement, exo controls panel “bunching” which can leave parts of the body
vulnerable, thus enabling the panels to protect against multiple hits. exo thus
adds to the vest’s ballistic protection without adding weight or thickness. exo
will be included in PROTECH’s tactical body armor in summer 2004 and will be
added to Safariland’s concealable products shortly thereafter.
Protective
Products International
Protective
Products International (PPI) introduces the Gladiator RHF. The Gladiator RHF
front opening vest features an ambidextrous rifle retention unit, concealment
for a hydration unit, and a canal for flex cuffs. Included in each Gladiator are
detachable throat, groin and upper arm protective panels.
Along with the
Gladiator, PPI offers the Armorlite LFT (Laminated Fabric Technology) Series, a
new ballistic package. The armor uses a new aramid fiber which totally
eliminates the need for quilt stitching which translates into lighter, thinner,
and more flexible body armor. The LFT Series is available in NIJ Threat Levels
II and IIIA.
Rabintex
Industries Ltd.
Rabintex
Industries Ltd. is introducing an integrated air circulation system for
ballistic vests. Showcased at the Eurosatory Exhibition in Paris, France, in
June, the patent pending Breeze Active Air Circulation System blows fresh air
into the vest’s front and rear inner layers. The product is based on the human
body’s natural cooling system, or the production of sweat for vaporization.
Because ballistic vests prevent this cooling process, wearers’ bodies are taxed
unnecessarily. The Breeze circulates fresh air between vest and clothing,
replacing the moisture saturated air, and restores the natural cooling system.
The Breeze runs on common AA batteries and weighs less than .8 of a pound. It
can provide ten hours of power in two modes.
Test subjects
marched for three hours in a room set at 86º F and 50% relative humidity. When
using the air circulated vest, the subjects’ heart rates, body temperatures and
even sweating were reduced. Company executives say the addition provides a
“genuine ‘no vest’ feeling,” and note that the Breeze meets all safety
standards, so it’s easy to add to most common ballistic vests.
RBR Tactical
Armor, Inc.
RBR’s tactical
vest line now offers new load bearing tactical vests, along with body armor
systems for first responders and perimeter forces. Two of RBR’s hybrid armor
systems, which combine aramid fibers woven with unidirectional technology,
recently earned NIJ Level IIIA certifications. Additionally, RBR is offering the
following body armor systems:
Designed for
Special Operations groups of the coalition forces in Iraq and Afghanistan, the
203-40 Light Assault Vest brings concealed armor’s weight, comfort, and low
profile to vests designed for high-speed tactical operations. The 203-40’s 1000
denier Cordura outer shell, which features modular pocket attachments, offers
front, back, and side protection, and allows for the insertion of rifle
protective plates.
RBR Tactical’s
newly redesigned face shield line offers riot, fragmentation, and Level IIIA
bullet protection in a universal strap mounted shield. Designed to fit most
ballistic helmet styles, the new system features a liquid barrier and allows
the shield to be locked into three different positions. As for ballistic
helmets, RBR’s Urban Tactical line of boltless helmets is a new addition. The
2.6 pound helmet features a net mesh crown cover and leather covered padding at
the same time that it provides full Level IIIA protection. The three-point head
harness can be installed without drilling a single hole.
Reliance Armor
Systems, Inc.
Reliance’s Stab
Armor vest is rated according to the NIJ 0101.15 Standard and provides both
spike and edged blade protection in a single vest. Its comfort features include
laminated fabric and foam, along with a custom fit and precision stitching which
also helps keep the vest in shape when it’s not being worn. It weighs just .38
pounds per square foot, and its resistant panels are sealed in an antimicrobial
and antibacterial pouch to keep it odor-free.
eliance’s
Softouch armor is a hybrid of Twaron 2000 Hi-Tenacity fabric and Gold Flex
laminated fabric. Certified in Threat Levels IIA, II and IIIA, Softouch offers
standard features which include a removable strapping system, soft trauma insert
included in the ballistic panel, and reinforced stitching.
Reliance also
offers a firearms instructor vest. Along with its safety orange offering, it
includes a split front with a slide fastener; solid front ballistic panel and
front rifle plate pocket; the ability to transfer concealable ballistic panels;
front and back sign attachments; and a belly band (cummerbund) attachment system
to secure the wearer’s back.
All three vests
come with Reliance’s TRANSPOR® “moisture
management” lining which allows moisture to evaporate rather than just wick away
from the skin.
Safariland® Ltd.,
Inc.
Safariland’s
Matrix technology, available in five of its ballistic systems, now offers a more
conventionally fitting shape. With adjustable shoulder and waist straps, a
ripstop outer shell, Comfort Cool inner wicking mesh, and inclusion in the Size
Right sizing program, the Matrix is flexible to a variety of body shapes and
sizes.
Second Chance
Body Armor, Inc.
Second Chance
recently announced its Sixth Generation Monarch Summit™ line
of body armor which is available in NIJ Levels IIA, II and IIIA. These vests,
15% lighter and 20% more breathable than vests in the Monarch product line with
the same Threat Levels, use the breathable aramid fiber, Twaron, made by Teijin
Twaron USA, and a water repellent fiber made by Simula, Inc.
TurtleSkin by
Warwick Mills, Inc.
Long known for
making needle-resistant gloves for law enforcement officers, Warwick’s
lightweight TurtleSkin material (recently used in the crash bags for NASA’s Mars
Spirit and Opportunity Rovers) is now available in stab-resistant ballistic
vests. The new patented TurtleSkin technology provides material so flexible that
it can be balled up in your hand. The softer material results in a higher degree
of all day comfort; at the same time, it provides Level III NIJ certified
comfort: It’s capable of stopping spikes when used in multiple layers. Body
armor manufacturers in the United States are currently using TurtleSkin
materials which include KEVLAR and Spectra fibers in their vests.
Under Armour®
Coming to Under
Armour’s fall product line are protective hoods featuring its transparent
Tactical Stealth Logo technology. The hoods provide full facial protection,
including below the neckline; a drop chin converts the hood to a neck gator.
Depending on the climate in which officers work, a ColdGear™ version
of the hood insulates in extreme cold, and the HeatGear® version
wicks moisture under headgear, as well as shielding against sand and dust.
U.S. Armor
Corporation
To keep up with
the recent surge in demand for its products, U.S. Armor is in the process of
dramatically expanding its production capabilities.
The company is
also currently testing a series of ballistic armor which utilizes new, enhanced
aramid fabrics. These will deliver aramid’s proven reliability while allowing
the wearer to enjoy the comfort and weight reduction provided by new weaving and
processing techniques for the fiber. The, as yet, unnamed product line will be
released shortly.
U.S. Armor also
offers a full line of antistab body armor. The company continues to be known as
“the custom shop” for user designed tactical armor. Additionally, U.S. Armor is
deeply involved in producing the revolutionary Baker Batshield armor for first
responders and tactical operators alike, along with U.S. Armor’s own line of
EOD/specialty products.
Future
Developments
In the movie,
Terminator 2: Judgment Day, the liquid-metal T-1000 seemed virtually
unstoppable. Physical weapons passed right through him, creating holes which
quickly closed back up. Although liquid-metal police officers are probably a
long way off, liquid body armor may not be.
The U.S. Army
Research Laboratory at the Aberdeen Proving Ground in Maryland and the
University of Delaware’s Center for Composite Materials have been jointly
working on such a project for the last three years. The goal is to make the
armor flexible and lightweight for normal wear, but for it to become rigid when
an object suddenly hits it. The idea is to use the liquid in sleeves and pants.
Hard particles
suspended in polyethylene glycol fluid, then soaked into layers of KEVLAR, can
stop an arrow’s penetration and the researchers are now seeking a way to fortify
it so it can stop bullets and shrapnel as well. Notably, the arrows (along with
ice pick stabs) virtually bounced off the treated KEVLAR, rather than being
slowed to a stop by the fabric layers.
The Industry as
a Whole
Olsen says that
body armor manufacturers are currently working with states and other purchasing
entities on developing new protocols for postpurchase testing. “The idea is
that, if a manufacturer is awarded a state contract, a plan will be in place for
ongoing testing over the life of the product,” he says.
As a direct
result of the Zylon controversy, the new protocols will eliminate what some
agencies and officers felt was necessary, but unscientific, testing of ballistic
vests. Rather than strapping a vest to a tree and firing bullets at it, the
protocol would be to regularly send (used) vests back to the manufacturer for
controlled environment testing. “In order for the program to work,” says Olsen,
“the agencies have to take some responsibility. The manufacturer has no control
over the wear and maintenance of the vests during the warranty period.” To that
end, he says, “This will be a cooperative effort between the manufacturer and
the purchasing agency.”
About the
Author: Christa M. Miller (cmmiller@psouth.net) is a freelance writer based in
southern Maine. She specializes in public safety issues.
BODY ARMOR
SOURCE LIST
American Body Armor
An Armor Holdings, Inc. Company
3120 E. Mission Blvd.
Ontario, CA 91761
Phone: (800)347-1200
Fax: (800)366-1669
Web site:
www.americanbodyarmor.com
E-mail:
contactus@armorholdings.com
DSM Dyneema LLC
1101 Highway 27 S.
Stanley, NC 28164
Phone: (800)883-7404
Web site: www.savemorelives.com
DuPont Advanced Fiber Systems
5401 Jefferson Davis Highway
Richmond, VA 23234
Phone: (800)453-8527
(800)383-4400
Fax: (800)787-7086
Web site: www.dupont.com
E-mail: afscdt@us.dupont.com
ForceOne LLC
428 Balsam Ave., Ste. B
Spruce Pine, NC 28777
Phone: (828)766-7675
(800)462-7880
Fax: (828)766-7678
Web site: www.forceonearmor.com
E-mail: hank@forceonearmor.com
Gator Hawk Armor, Inc.
1806 Goodyear Ave.
Ventura, CA 93003
Phone: (866)GTR-HAWK
(805)639-0841
Web site: www.gatorhawkarmor.com
E-mail:
scotty@gatorhawkarmor.com
Instant Armor Inc.
350 East Easy St. #1
Simi Valley, CA 93065
Phone: (877)BLT-PRUF (258-7783)
Fax: (805)526-9213
Web site: www.instantarmor.com
E-mail: ebm@instantarmor.com
K9 Storm Inc.
3rd Fl., 110 McDermot Ave.
Winnipeg, MB R3B 0R8 Canada
Phone: (204)669-8199
Fax: (204)668-2291
Web site:
www.k9storm.com
E-mail: info@k9storm.com
Pinnacle Armor
P.O. Box 5839
Fresno, CA 93755
Phone: (559)292-3185
Fax: (559)292-3187
Web site: www.pinnaclearmor.com
E-mail: murray@pinnaclearmor.com
PROTECH Armored Products
An Armor Holdings, Inc. Company
158 Hubbard Ave.
Pittsfield, MA 01201
Phone: (800)234-3104
(413)684-3104
Fax: (413)684-4166
Web site:
www.armorholdings.com
Protective Products International
1157 Sawgrass Corporate Pkwy.
Sunrise, FL 33323
Phone: (800)509-9111
(954)846-8222
Fax: (954)846-0555
Web site: www.body-armor.com
E-mail: sales@body-armor.com
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