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Customization of a lightweight ballistic vest

Conference Paper · November 2008

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 2nd International Scientific Conference Textiles of the Future

CUSTOMIZATION OF A LIGHTWEIGHT BALLISTIC VEST

F. Boussu, A. Ragot, M. Kulinska, X. Legrand, P. Bruniaux.
Univ. Lille North of France, F-59100, ROUBAIX, ENSAIT, GEMTEX,

ABSTRACT

Protective clothing is designed for bullet, stab, puncture or impact protection for police and
military staff. In the ballistic application, the kinetic energy is absorbed by the body armour
panel. The actual norms ensure a maximum affordable value for the body penetration which is
directly responsible of the blunt trauma. All the existing body armour solutions ensure the
same level of protection on the entire body surface.
The main objective of this study is to optimize the design of a ballistic vest by using the real
3D measurement of the body to protect and ensure an efficient lightweight and customized
protection. Thus, main parts of the body can be differently protected to the bullet penetration
due to the different distribution of ribs, blood vessels and flesh of the human body. The final
solution is more flexible and suitable than the existing solutions.

1. INTRODUCTION

As an increasing trend, more and more women will be enrolled in the army and military
positions. For instance, in the French Army, the evolution can be evaluated from 1987 with
around 18000 women (about 7%) to 2003 with 44500 women (12,7%) and currently about
18% [1]. To ensure a safe protection against the ballistic threat (conventional ammunitions),
protective clothing must be adapted to the woman morphology. It can be seen several
solutions adopting the female shape and having a good protection/comfort ratio [2]

Figure 1. (Left) adding darts to chest level (middle) setting-up lateral panels (right) thermoforming the chest

Thus, different devices can be found in the existing solutions. A brief state of the art and a
techno-economical survey of the ballistic vests shows that the main idea leading to the design
of the vest is apparently the same for every solutions: the same level of protection for every
part of the body. It can be understood that every part of the body will react at the same level.
The proposed study on the design of a new ballistic vest for woman (or man) tends to
optimize the level of protection with respect to the expected energy absorption behaviour of
the different parts of the body. The expected results are an optimization of the blunt trauma, a
global weight reduction of the ballistic vest and an increase of the comfort.

2. DESIGN OF BALLISTIC VEST

 2nd International Scientific Conference Textiles of the Future

2.1 Sizing

The standard sizes are XS to XXL. In order to give a range of sizes, some manufacturers have
a size chart, where all the sizes correspondences appear. For example Global Armor [3][4],
depending of the waist, the chest and the back length, has 100 different sizing options to cater
for all requirements. The new anti-fragmentation for Canadian Army exists in 17 sizes. That
confirms the trend to very personal protection. It is an advantage for Police forces to be
protected in the best way, but it is also a disadvantage in the Army because of the number of
soldiers. So best size fit is needed for more soldiers.
A new program called ProFit is purposed only for Sigma Six and Delta Five vests [5]. The
aim is to have a better knowledge of the customer’s sizes and needs in order to improve their
vests.

2.2 Body measurements

The ballistic vests are no longer unisex. Many companies offer female vests because women
are often more fine and are also embarrassed if the bust is crammed into the vest. But in order
to ensure the better fit to the wearer, the trend is now to fulfilled an order request where all the
measurements are asked (see sizing tables [ 6][7][8][9])
Chest circumference and torso length determine the size of the vest, sometimes also the waist.
So if you just want an occasionally vest, those three information are sufficient. But if you
wear it permanently while working, you may want to have a good comfort too. That is the
reason why manufacturers propose now special sizing sheets on websites.

Figure 2. Measurements body for a better fit (http://www.globalarmour.com/measurements.php)

It’s just necessary to fill in the measurement sheet with the different lengths: measure around
the body at the fullest part of the breast and under the arms with empty pockets, waist,
measure from the V-notch which is at the top of the breast bone at the base of the neck to the
top of the duty belt; and also your height, weight and bra size for women. To be sure those
measurements are correctly taken; it is advised to ask a second person for help.

By sending back this document, an estimation can be provided (especially for oversize) and
then, receive a product made just for the exact body, with the perfect fit. Another society,
Tote Systems Australia [10], proceeds also in this way, but with four more measurements for
the female vest (shoulder seam to nipple, nipple to the top of the duty belt, nipple to nipple
and measure around the chest underneath the breast).
 2nd International Scientific Conference Textiles of the Future

Figure 3. Measurements body method for woman http://www.tote.com.au/female_measure.htm or man

http://www.tote.com.au/measure.htm

The way to measure is also described in the sizing sheets [11][12][13][14][15].

It can be highlighted two advices: always wear the security belt if you have one, and measure
at the quiet respiration.
For men and for women, the asked measurements are not exactly the same. More details are
required to make a female vest, mainly due to the chest complex shape.

For women For men:

1 Height 1 Height
2 Weight 2 Weight
3 Cup Size 3 Chest Circumference
4 Bust 4 Waist Circumference
5 Under bust 5 Chest Breadth
6 Waist size 6 Front Length Standing
7 Chest Breadth 7 Front Length Sitting
8 Front Length Standing 8 Back Length Standing
9 Front Length Sitting
10 Back Length Standing
11 Bust Height Standing
12 Bust Height Sitting
13 Bust Width
14 Bust Coverage
15 Side Height Standing
Table 1. Measurement values needed for woman and man.

2.3 Influence of parameters

Before designing a personal protection it's important to consider 4 main factors, which are the
price, the performance, the weight and the comfort. Parameters having an influence on these
factors are listed respectively below.
For the Price:
- the used materials (fabrics, UD, yarns),
- the protected areas,
- the numbers of layers,
- the position of panels during the cutting (to minimize the waste),
- the transformation, assembling and making costs.
For the Performance:
- the material link and type (panels, stitching),
- the number of layers,
- the protected areas,
 2nd International Scientific Conference Textiles of the Future

- the layers pilling up,

- the type, position and alternation of darts,
- the bonding of layer (stitching, quilting, sticking)
For the Weight:
- the materials (density, weight),
- the number of layers,
- the protected areas,
- the bonding of layers (stitching, quilting, sticking)
and for the Comfort:
- the total weight of the vest,
- the shape of the vest,
- the type and the position of darts,
- the protected areas,
- the number of layers.

2.4 New ballistic solution

From all these previous studies and documents, the design of a new ballistic vest consists
in first to delineate the various protection areas, on a virtual 3D dummy.

Zone 1

Zone 2

Zone 3

Figure 4. Global configuration of the front (left) and back (right) protection of the vest.

According to the description of several type of protection (NIJ norm [16]) and to
correspond to a bullet-proof vest of level IIIA, the chosen materials are a plain weave
para-aramid fabric (Kevlar type, 110Tex) of 195g/m² and a thickness of 0,5mm and a
UHMWPE unidirectional fabric of 175g/m² and a thickness of 0,2mm.
The distribution of these materials can be optimized per zone as:
ZONE 3: 20 plies of para-aramid fabric
ZONE 2: 20 plies of para-aramid fabric + 5 plies of UHMWPE UD
ZONE 1: 20 plies of para-aramid fabric + 10 plies of UHMWPE UD
This new configuration of the different materials with respect to the different protection levels
leads to different estimated surface mass per zone, like:
ZONE 3: 3,9 Kg/m²
ZONE 2: 4,7 Kg/m²
ZONE 1: 5,6 Kg/m²
 2nd International Scientific Conference Textiles of the Future

Then the designed solution must lead to more comfort thanks to the described approach:
To design a correct pattern for woman’s ballistic vest, a virtual 3D female dummy
available on the software Design Concept is used to create the sufficient surface to drape the
garment on.

Figure 5. (left) measurement values (middle) fit on virtual dummy (right) final drape

The different zones have been delineated to specify the various darts positions (only for the
para-aramid fabrics) to conform to the shape of the female body and not to avoid the ballistic
protection efficiency.
Dart n°10

Dart n°9

Dart n°8

Dart n°7

Dart n°6
Dart n°5
Dart n°4
Dart n°3
Dart n°2

Dart n°1

Figure 6. distribution of darts to optimize the tensile strength of the global vest.

A set of layers defining the alternation of darts and the position of layers in the stratification is
given.

Figure 7. (left) layer # 2 (p-aramid) and (right) layer # 4 (p-aramid) to protect the zones 1, 2 and 3
 2nd International Scientific Conference Textiles of the Future

The Alternation of the darts is:

Layer # 1 <=> dart n°1,
layer # 2 <=> dart n°6,
layer # 3 <=> dart n°2,
layer # 4 <=> dart n°7,
etc ...

Figure 8. (left) layer # 12 (UHMWPE UD 1) (right) layer # 30 (UHMWPE UD 2)

in white to protect the zones 1 and 2 in white to protect only the zone 1

A complete board of the ballistic configuration has been achieved including the alternation of
darts, the interval value in mm between the first layer and another, the layer's surface in mm2
computed by the software, and the resulting weight. The first ten layers made in para-aramid
are stitched (in the shape of 3 cm side lozenge) to improve the non-penetrating of bullets.
Then, the layers of UHMWPE UD are thermo stuck on the respective inferior layers.

Thus, the protected surface of the front vest is around 1900 cm² compared to a standard vest
(level IIIA of protection) which can be spread between 1500 to 1800 cm²
The estimated weight of the ballistic components leads to a value of 750 g compared to a
standard vest (level IIIA) which can be 700 to 1000 g.
According to the description of the ballistics vest currently used in France, it can be observed
that the total weight is 4,9 Kg/m² compared to the proposed solution of 3,9 Kg/m²
This corresponds appreciatively to a benefit of about 20% in weight.
This weight reduction contributes to a better comfort and a decrease of the costs of the raw
materials.

3. CONCLUSION

A new approach has been proposed to better introduce the different personal parameters of the
body inside the new geometric definition of the vest. The optimization of the protection zones
of the global vest and the assembly process lead to a reduction of weight and contribute to a
reduction of the waste quantity during the cutting operation. The achievement of a gradient
protection at the chest level helps also to avoid a failure in the protection like done with the
shearing stress.
Afterwards, it can be possible to create a base virtual dummy with scalable measurements,
depending on a certain number of measures in order to recreate the internal surface of the
bullet-proof vest. The use of a virtual body given by the Body Scanner to make tailor-made
bullet-proof vest to more comfort can improve the measurement process to accelerate the
sizing process.
 2nd International Scientific Conference Textiles of the Future

4. REFERENCES
1 Place des femmes dans la professionnalisation des armées (rapport 2004),
http://www.c2sd.sga.defense.gouv.fr/IMG/pdf/c2sd_synth_loriot_choix_femmes.pdf
2 http://www.securityprousa.com/feboarve.html
3 Armorshield USA (http://www.armorshield.net/ - Quick Links
4 Global Armour (http://www.globalarmour.com/measurements.php )
5 Pacific Savety Products (http://www.pacsafety.com/products/armor_sizing.htm)
6 http://www.uscav.com/prodinfo/pdfs/Armorshield_sizechart.pdf
7 http://www.globalarmour.com/armour-overview.php
8 http://www.army.forces.gc.ca/Chief_Land_Staff/Clothe_the_soldier/hab/PDF/FPV-guide_ef.pdf
9 http://www.dnd.ca/site/community/mapleleaf/vol_8/vol8_42/842_12.pdf
10 Tote System Australia - The Armour Specialists (http://www.tote.com.au/body_armour.htm )
11 http://www.globalarmour.com/measurements.php > Male & Female sheet
12 http://www.tote.com.au/measure.htm > Male measure sheet
13 http://www.tote.com.au/female_measure.htm > Female measure sheet
14 http://www.armorshield.net/ASMSS%2003072007.pdf > Male vest sizing worksheet
15 http://www.armorshield.net/ASFSS%2003072007.pdf > Female vest sizing worksheet
16 National Institute of Justice, Ballistic resistance of Police Body Armor, NIJ standard 0101.03, April 1987.

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