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Is Soft Body Armor Comfortable to Wear?

Is soft body armor comfortable to wear? What NIJ-funded research and an officer survey say about comfort, fit, weight and heat, and how to judge a vest for everyday wear.

ArmorList Editorial·November 4, 2024·7 min read

Soft body armor is worn by law enforcement officers, security personnel and some civilians. Comfort matters because, in our view, armor that is uncomfortable is armor people loosen, adjust or leave off. Officers say so themselves: in an NIJ-funded survey by the Police Executive Research Forum (PERF), run from October 2010 to May 2011, the features officers most wanted in the next generation of body armor were improved comfort (84.4 percent), improved fit (72.6 percent) and reduced weight (63.9 percent).

How comfortable a given vest is depends on the type of armor, its fit, the conditions and the person wearing it. This article sets out what published research says about each, and labels our own advice as ours.

What is soft body armor

Soft body armor is flexible armor made from layers of high-strength fibers. Two fiber families come up again and again: aramids, sold under trademarks such as Kevlar and Twaron, and ultra-high-molecular-weight polyethylene (UHMWPE), sold under trademarks such as Dyneema and Spectra. A trademark names the fiber family; it is not a rating. Hard armor, by contrast, is rigid plates of materials such as ceramic, steel or polyethylene.

CJTTEC, which administers the NIJ Compliance Testing Program, says NIJ 0101.07 names its levels "HG" for handgun and "RF" for rifle, "a reduction in soft-armor levels and an additional hard-armor protection level". In our view, soft armor should not be relied on against rifle rounds unless the model's own record names them. For more on the rifle levels, explore our article on Breaking Down Hard Body Armor Levels.

Types of soft body armor

The most common form is the vest, which covers the torso and is usually worn under clothing for concealment. CJTTEC says concealable armor is worn under the duty uniform, while external carriers are worn over it, are a bit larger and usually thicker, and are often made of material that matches the uniform shirt. Coverage varies by model, and some add side or shoulder protection.

Soft panels are also sold to go into backpacks, jackets or other items. The Department of Justice has said that NIJ has never tested nor certified ballistic items such as backpacks, blankets or briefcases, other than body armor for law enforcement; a panel's level in a bag is what its own test report shows.

Tactical carriers often add webbing in the style of MOLLE for attaching gear. To learn more, check out our post on The Function and Benefits of Molle Straps.

Key features to consider

First, the level of protection. A level names the rounds the armor was tested against under a named standard: Levels IIA, II and IIIA under NIJ 0101.06, and HG1 and HG2 under NIJ 0101.07. The right level depends on the threats you assess, not on what most people buy. Where a buyer, policy or funder requires NIJ compliance, as the Bulletproof Vest Partnership (BVP) does, check the exact model on NIJ's Compliant Products List (CPL), with the date you read it. For a model outside the NIJ program, check the standard it claims and the lab report behind it.

Second, fit. The Bureau of Justice Assistance (BJA) requires BVP-funded armor to be "uniquely fitted": correctly sized panels and carrier, determined through appropriate measurement, with properly adjusted straps and fasteners. In our view, adjustable straps and closures are what let a correctly sized vest sit right on your body.

Third, the carrier fabric. In our view, a moisture-wicking or breathable carrier can help on long wear in warm weather; ask the maker how it was evaluated. For guidance on fit, see The Right Way to Fit Body Armor.

Comfort factors

Comfort is subjective, but some factors are measurable.

Weight. NIJ notes that thickness and material type are closely tied to the weight of body armor. A 2017 systematic review of studies on law enforcement personnel found that body armor increased perceived exertion and the time needed to complete functional tasks, and reduced balance and stability. Weight varies by model and level: compare the figures the maker states for the exact model and size.

Heat. NIJ notes that thicker armor may trap more heat against the body and may be stiffer, and NIJ has funded research on how armor affects officers' core body temperature in real-world conditions. NIOSH says wearing certain protective equipment and clothing can increase the risk of heat-related illness.

Movement. In a 2009 study listed by NIJ, concealable armor measured close to no armor on upper body range of motion, while external armor lowered it on most measurements.

For more on materials, consider reading Materials Used in Armor Plates Explained.

What wearers report

The PERF survey above is the clearest record we found of what officers want: comfort and fit came first, ahead of weight. In our view, wearers who find the right size and cut tend to describe armor as part of their routine, and those who do not describe it as restrictive, especially in hot weather or during physical work. Comfort is individual, so try more than one model and size where you can.

Pros and cons of wearing soft body armor

In our view, the advantages are protection against the handgun threats the model was tested to, concealment under clothing, and a weight that can be carried through a full shift.

The limits are real. Soft armor is not rated against rifle rounds unless its record names them, and a ballistic rating does not cover knives: NIJ keeps a separate standard and list for stab resistance (NIJ 0115.00). Heat and stiffness, as above, can make armor uncomfortable in some conditions. Cost varies by model; for more, see What Does Body Armor Typically Cost?.

Tips for improving comfort

  1. Get the fit right. ASTM E3003 sets out how to measure a wearer for body armor, and the Personal Armor Fit Assessment, a checklist excerpted from it, checks coverage standing, seated and in working positions.
  2. Our advice: wear a moisture-wicking layer under the armor to manage sweat on long wear.
  3. Our advice: re-adjust straps and closures when what you wear underneath changes, so the armor stays in place without restricting breathing.
  4. NIOSH recommends water, rest and shade, and work-rest schedules adjusted for the clothing and protective equipment worn. Take armor off only where it is safe to do so.

How to choose the right armor for you

Start from the threats you assess, then the time you will wear the armor. If you will wear it for long periods, in our view comfort, breathability and weight belong in the decision alongside the level. Try different sizes and models to find the one that fits your body.

Then check the record of the exact model: the standard and level it is listed or tested at, and, where NIJ compliance is required, its CPL status and the date you read it. The CPL answers whether a model met NIJ's program; it is not the only evidence of quality. For more, see Understanding Body Armor Ratings.

Common misconceptions

"All body armor is uncomfortable and bulky." Officers' own answers in the PERF survey show comfort is a real concern, and the 2009 study shows concealable armor costs little range of motion. In our view, a vest that fits and suits the conditions is wearable for a full shift.

"Soft body armor is bulletproof." NIJ says no body armor is bulletproof. Armor is rated against the rounds its level names, and nothing more.

"Body armor is only for police or the military." Federal law does not limit body armor to police or the military, but it does set limits: 18 U.S.C. § 931 bars people convicted of a felony crime of violence from purchasing, owning or possessing it, and some states add their own rules. This is general information, not legal advice.

Conclusion

The comfort of soft body armor depends on fit, weight, heat and the person wearing it, and officers rank comfort and fit high on what they want improved. Choose by the threats you assess and the time you will wear it, measure and adjust to the fit guidance, and check the record of the exact model.

Sources

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