How is Bulletproof Clothing Made? The Ultimate Behind-the-Scenes Look

I'm going to do a safe bet that when you read or hear the term bulletproof clothing, there’s a certain action movie franchise that comes to mind.

And yes, the suit looks great, and those special effects are outstanding, but they’re just special effects. Bulletproof clothing is much different in real life.

So what are they and how is bulletproof clothing made, you ask? In this article, you'll learn how manufacturers go from a liquid chemical blend to a bullet-resistant shield that parents, kids, and regular civilians alike can wear daily for the ultimate protection.

The Truth About Bulletproof Vests and Bulletproof Clothing

Bulletproof clothing consists of engineered plastics and special ballistic fibers layered together to provide protection. The raw materials are typically cut and sewn into shirts, hoodies, or jackets. For added protection, a plate carrier pocket may be sewn into the fabric where ballistic panels are then inserted.

Because of the lightweight materials used, bulletproof clothing offers more mobility and covert options than a bulletproof vest which tends to be overt and bulky.

Bulletproof vests offer more options for the variety of threats a person could face. Vests may contain hard or soft plate armor for additional protection and the ability to attach gear directly to the vest.

A Bulletproof vest may be worn over or under clothing providing a somewhat covert appearance with higher protection than a bulletproof t-shirt or hoodie. Regardless of the end result , much of the manufacturing process is similar for clothing, vests, and panels.

Raw Materials Used

The most important part of what makes anything bulletproof is the materials used. Truth is, no matter how many layers you make or how intricate and tight your stitching is, you're just not going to make silk strong enough to stop bullets.

There are two major types of raw materials used to make bulletproof clothing and vests.

Ultra-High-Molecular-Weight Polyethylene (UHMWPE)

Typically known by a more popular brand name Dyneema®, UHMWPE is produced by spinning a specialized gel into fiber. This fiber when woven together and layered is extremely lightweight and strong.

The gel consists of long strands of polyethylene chains all aligned in the same direction. The length of these chains is what gives it its strength.

Due to the length of the chains, there is a significant overlap between the chains. These overlaps ultimately make the material stronger than high-density polyethylene but more lightweight. Recent years have seen an increase in popularity among bulletproof clothing manufacturers.

Aramid Fibers

Aramid fibers were originally introduced in the 1970s as a stronger alternative to nylon. Aramid fibers differ from nylon with the presence of aromatic rings of six carbon atoms. The rings are connected by amide linkages compromising a CO group attached to an NH group. If less than 85% of the amide linkages are attached to two aromatic rings the material is classified as nylon.

To create aramid fiber the compound is first turned into a liquid chemical compound. The liquid is spun into a solid thread. The individual threads are further spun together to form the fiber. The most common brand of aramid fibers is Kevlar®.

Manufacturing

While the fibers mentioned above are strong and used to make bulletproof clothing, the materials still need to be turned into something usable. At this point, the fiber is woven into a fabric and sewn into layers. Sounds simple enough right?

Let's dive in a bit deeper...

Creating the Panels

To create the ballistic panels the layered sheets must be heat sealed in a process called lamination. Using specialized equipment manufacturers heat the fabric layers together and then apply extreme pressure to fuse the layers together.

Once the layers are heated and fused the newly created ballistic panel is given a cooling bath for hardening. This allows the ballistic panels to provide the required protection while being lightweight and offering maneuverability.

Covering

Once the sheets have been layered they must then be placed into a protective cover. Similar to a pillow case the newly created ballistic material is placed inside and heat-sealed. The cover is necessary to protect the ballistic panels from UV light and moisture.

Once inside the cover, the ballistic panel is complete and ready to be integrated into the clothing.

From Panel to Clothing

At this stage expert ballistic tailors are hired to stitch the panels and clothing together. The panels are cut and shaped to the clothing pattern. To incorporate them into the t-shirt or hoodie the ballistic panels are either box or quilt stitched.

The choice depends on the final product. For more mobility and comfort box stitching is the best option. However, quilt stitching offers better protection and is less likely to shift and move about uncomfortably while worn. This is because it produces a stiff panel which also makes it the more labor-intensive of the two.

Panel Inserts

Some bulletproof clothing consists of panels inserted into the fabric or a plate pocket for added protection. To achieve this the tailor sews pockets in the front and back of the material. The panel is then inserted inside this pocket.

Often jackets will include this added protection. This is because adding panels in this way increases the bulk of the product. Making it less covert. Jackets are bulky by nature and better conceal the panels.

These bulletproof panels go through certification testing designed by the National Institute of Justice (NIJ).

NIJ Standards and Certification

Some manufacturers do not always have their bulletproof panels certified by the NIJ before selling, but obtaining this certification is an important step. The NIJ has developed a standardized way to ensure that the product being purchased will do as promised.

Manufacturers may choose to send their products for testing according to NIJ standards. Once the results are reviewed, a protection level is determined. These protection levels indicate which type of threats each product is best suited to protect against, providing assurance to military or law enforcement agencies and other buyers of the product’s effectiveness.

Once certified and assigned a protection level, the NIJ adds the products to its public list of compliant manufacturers. Anyone wishing to find out if an article of bulletproof clothing is truly certified may find out on the NIJ's list.

And That's How...

Bulletproof clothing is made through a complex process that starts with a liquid chemical blend and turns into a final product capable of stopping bullets. When it comes to ensuring your safety in an ever-increasing unsafe world, it's important to know that what you are buying to keep you safe will do just that.

Now that you know how bulletproof clothing is made you should feel more confident and secure browsing our collection of bulletproof clothing to meet your needs.

If you still find yourself with a question or two contact our experts immediately, we're here to help!