Best Body Armor [Tested]: Hard Plates & Soft Armor By: Allison

Body Armor Laws in the U.S.

There’s a myth that it’s illegal for civilians to own body armor, and it certainly seems true when you’re shopping around.

Some companies will only sell to you with the proper documentation indicating your status as an LEO or military member.

Truth is — all civilians in the U.S., with the exception of felons, can legally own body armor.

There may be some local regulations, so you should check out your local laws to make sure you’re in the clear. Don’t just take our word for it.

And unfortunately, after mass shootings…there’s been some lawmakers calling to add body armor regulations on regular civilians.

Do I Even Need Body Armor?

Will I become bulletproof with body armor?

In short–no. They’re bullet-resistant, meaning that they increase the rates of survival, decrease the severity of injuries that occur, and give you a better chance. 

All body armor can be defeated–it may just be a matter of what is shooting at it or how many times you’re hit.

And don’t think you can simply get up after getting shot while in body armor…chances are you’re going to be in a world of pain with possible broken ribs and internal bleeding.

That’s a TV/movie trope. And lastly…be sure to check out threat level ratings when shopping for armor, too. Get the level that is appropriate for the types of threats you might face.

Now…let’s squash some misconceptions about body armor legality.

Even if you don’t work in a vocation that requires protection from flying lead, there are still plenty of reasons to want a set of body armor…

The main one is…because you can. Second, you’ll look cool. But here are some of our other favorites…

SHTF

Ok, let’s get this one out of the way… there are some pretty inexpensive (and long-lasting) hard plate body armor packages if you’re planning on protecting your home or roaming for supplies.

Home Defense

You probably don’t have time to don some armor…but peace of mind is a good reason. I recommend a Tough Hook system.

Range Safety

You’ll probably look more like a goober if you’re donning plates at the local range. But if you shoot in the open (or go to terrible ranges)…it doesn’t seem that bad of an idea.

Larp-ing

Live action role-playing…uh, yea…we don’t do this…we swear 🙂

Competition

The main reason for our team wearing body armor. It gives you a workout, an excuse for why you were slower than your buddy, and protects against potential negligent discharges.

Our editor Eric always wears his for night shoots, as do most of his squad…

And now… there are new competitions called Tactical Games which mix CrossFit and shooting…where you gotta wear a 15+ pound rig.

The training begins! But first…what are the two biggest types of body armor?

Soft Armor vs. Hard Armor

There’s a staggering variety of body armor types and rating codes, so don’t feel bad if you’re left scratching your head.

We’re going to break down the details a bit for you. One of the first categories you’ll discover is soft vs. hard armor. 

Police officers and anyone looking for a more comfortable but less protective armor option usually goes with soft armor. It’s made out of a flexible, incredibly strong woven net fabric (like Kevlar) that stops the projectile and spreads its impact energy across the entire vest.

This type of armor is commonly found in complete vests but also can be found in inserts that can be added to bags, carriers, or behind stronger plates.

Soft armor can protect against many pistol calibers, as well as other threats like knives (if rated) and debris.

Hard armor is…hard.

It’s also harder to conceal, but it offers far more protection.

It is constructed from either steel plates, ceramic composite, or ultra-high molecular weight polyethylene (plastic).

Generally, hard armor plates are worn in a plate carrier, which is a vest that fits over your other clothing.

Hard armor plates have a variety of ratings, but the strongest can stop some pretty serious rifle rounds.

Body Armor Threat Levels

Body armor levels are yet another confusing aspect of shopping for armor.

These standardized ratings, however, are set by the Department of Justice’s National Institute of Justice, based on tiers of threats. 

Even with these ratings, it’s important to keep in mind that a combination of factors can affect the effectiveness of a vest. These include but are not limited to bullet material, bullet mass, and especially velocity.

That’s why when you dig down into the weeds…the ratings are set for certain calibers AND velocity.

Unfortunately, that means even if you have a protection level for a certain round…if you’re too close and the round hasn’t had time to slow down…you’re still screwed.

Our recommendation is to check the manufacturer in the NIJ’s database (slow load) of tested companies and body armor models. All of our choices down below are already vetted!

The body armor industry has stepped up with its own III+ rating, which falls somewhere between the NIJ Level III and Level IV ratings. Just know that this rating isn’t made by the NIJ, and it can differ between companies.

Here’s one example:

Check out more details on body armor levels, common threats, and a huge list of body armor at The Prepared. Now…what do we recommend?

Go with Level IIIA soft armor if you only think you’ll have handgun threats…or if concealment is the priority.

For best bang-for-the-buck hard armor…go with Level III+ that stops 5.56 M193 and M855 since those are relatively common rounds. Some brands will also call them “special threat” protection.

For max protection…or if for some reason you’ll be against true armor-piercing rounds…get something Level IV ceramic.

Keep those in mind as we dive deeper into the world of body armor…

What is Body Armor Made Of?

AR500 Steel Plate Armor

Armor made from material such as AR500 steel is the most affordable hard armor on the market at around $70-100 a plate (you’ll want a front and back).

But it’s also the heaviest at 8+ pounds for each plate normally.

It’s seriously durable since most range targets are constructed out of AR500. And it can also maintain its integrity for years if properly stored.

It can stop almost all handgun rounds and most non-armor-piercing rifle rounds. But one threat to keep in mind is very high-velocity rounds such as the 5.56 M193, which can still zip on through Level 3 armor.

It’s a small hole…but it went right on through…

Another thing to consider is spalling, or the frag that flies off from a hit.

Even if the round doesn’t penetrate your armor…you’re going to have a bad day if sharp metal hits your throat and face.

Enter Paxcon or any other kind of surface spray for AR500-based armor. It helps keep in the spalling…but we’ve found you want the build-up layer for it to be truly effective.

You can hope your carrier catches the majority of it…or suck it up and get the build-up.

Ceramic Armor

If money is no object, ceramic armor can stop some pretty extreme bullets, like the fast M193 and M2AP (30.06 armor-piercing).

The trade-off is that this is the most expensive at $200+, the bulkiest option in terms of thickness — but it is lighter and is normally Level IV.

Ceramic armor isn’t the most durable…so if you drop it or fall on something while wearing it…you will likely have to replace it.

It’s also mostly rated for a single hit or multi-hits not in the same area. The lighter, thinner, and more hits a ceramic plate can take…the more it’s going to cost.

We go super in-depth Testing Ceramic and UHMWPE Armor here.

Ultra High Molecular Weight Polyethylene Plastic (UHMWPE)

Plastic may not seem the most protective, but it falls somewhere between ceramic and steel on factors like cost and durability. UHMWPE plastic is super light at around 3 pounds a plate–it even can float on water.

But it is a great deal thicker than its steel counterparts.

Common rounds, like the M855 green tip, may punch through plastic, but it offers protection from pretty much all pistol calibers. It stands up to repeated shots but only about as well as ceramic.

How to Fit Body Armor

Obviously, the better fitting your armor is, the more comfortable it will be and the better protection it will offer.

Too large or too small plates may not cover you properly, and poorly cut shapes can restrict your movement or leave uncomfortable pressure points.

Here’s what to look at when it comes to choosing the right size of armor.

Sizing

There isn’t really an industry standard when it comes to sizing plates, and wrong-sized plates usually can’t be returned for safety reasons, so you want to get it right the first time.

10” by 12” is the most common armor plate size, along with tiny bois (8” by 10”) and big bois (11″ by 14″).

You can find other sizes, as well, but these are the easiest. Pay attention to the manufacturer’s sizing charts, and get a little help measuring yourself if you need it.

You want to be sure that the armor plate touches your sternal notch (follow down from your Adam’s apple to where you’ll gag when you press in).

You’ll also want the width to cover your nipples. It’s going to look a lot higher than you think.

The point of armor is to protect your heart and lungs, not your guts.

Cuts & Shapes

Most manufacturers produce armor in just a handful of shapes, but you’ll choose depending on the type of coverage you’re looking for and your body’s unique shape and motions.

These shapes are:

• Rectangular: These plates offer the most coverage but the least mobility. They’re also popular for back plates since they cover so much.
• SAPI: These plates offer a lot of the same coverage as rectangular plates, but the upper corners are removed to give you a better range of motion.
• Shooter: These plates are similar to the SAPI, but the corners are cut more aggressively down. May be handed, where one side is shaped differently to accommodate a buttstock for right or left-handed shooters.
• Swimmer: These plates are aggressively cut down on all corners, offering the least protection but the most mobility.

Again…it might vary among manufacturers who come up with their own cutesy names.

Curvature

Curved and flat plates both exist–but each has different uses. Plates can curve from top to bottom or from your chest to your belly, but they can also curve from side to side or shoulder to shoulder.

Your body is curved, so it’s well worth your comfort to spring for the curved chest plate, even if it’s a few dollars more. Curved plates are contoured to the natural shape of your body, so they often have the best fit.

Flat plates can be good for back armor, but you may still find that uncomfortable. Choose what fits your body best.

After all…you don’t want to feel miserable wearing it.

Choosing the Right Body Armor

Now that you have a grasp on all the intricacies of picking out body armor, it’s time to choose the right one.

Ultimately, it comes down to you–your protection needs, your budget, and your body. We’ve got a few recommendations…starting with soft armor, moving into hard plates, and then ceramic.

Final Thoughts

Choosing body armor isn’t something that should be taken lightly. After all, it’s your life you’re entrusting to a few inches of steel, ceramic, or plastic, so you want to feel confident in your decision.

We hope we’ve helped you find some great options, but be sure to do a little research into what threat protection level suits your needs and take time to measure yourself, so you can find the right armor plates.

For most civilians…we highly recommend AR500 Armor’s Level III+ Lightweight as the way to go. One more time for our video!