New Plastic Armor Lighter than Kevlar, Provides Same Protection

Lightweight plastic body armor will replace Kevlar-based protective equipment used by U.S. troops in 2019, reports Military.com .

The new Torso and Extremities Protection system, which has been undergoing field testing at bases across the U.S., weighs about 23 pounds — 25% lighter than gear worn today, said Lt. Col. Kathy Brown, a program manager for Soldier Protection and Individual Equipment at Program Executive Office Soldier.

It's unclear exactly how much the new gear will cost; however, Brown said it will be cheaper than the current equipment and offer the same level of protection.

The key to reducing body armor weight has been changing soft materials from Kevlar to polyethylene -- a type of plastic. The Army is also developing polyethylene helmets to replace the Kevlar versions, Brown said. 

The unisex body armor's design also takes into account earlier efforts to make items comfortable to the female form, Brown said.

"We tried to make sure our equipment was all-encompassing," she said. "Now we have a system that encompasses both male and female soldiers."

The system is slated to roll out in 2019.