Since DuPont first introduced poly-paraphenylene terephthalamide (K29) in 1971, it’s been known simply as “Kevlar.” Last year that changed when the company introduced “Kevlar Exo,” a new kind of DuPont ballistic protection material and the first Kevlar to be distinguished by name from legacy Kevlar.

“It’s a different chemistry. It’s a different manufacturing process. It’s all new,” says Steven LaGanke, DuPont global sector leader, explaining why Kevlar Exo warranted a change in branding. “Part of what we were thinking about when we came up with the name was we wanted to make sure people knew this Kevlar was different.”

There are some major technological advancements that went into the development of the new Kevlar, but what really differentiates Kevlar Exo from previous versions of Kevlar is its strength. It’s significantly tougher than the previous Kevlar. “Kevlar Exo is 30 to 40% stronger than our legacy Kevlar,” LeGanke says.

Using a stronger fiber in the manufacture of soft body armor will have two effects that people who wear bullet-resistant vests will love. It’s lighter and it’s more flexible.

In the past, reducing the weight of body armor often led to compromises in either protection level or flexibility. To get the most protection while reducing weight, the armor often had to be stiffer. Kevlar Exo changes that equation. LeGanke says Kevlar Exo’s strength gives the armor producers a material that can be more comfortable while offering the same level of bullet resistance.

Producing stronger armor material is even more crucial now that the National Institute of Justice (NIJ) is implementing its NIJ 0101.07 (NIJ 07) body armor evaluation standard. The new NIJ standard requires a much tougher testing protocol than the previous standard with more shots from different angles and more lab-simulated wear and tear on the vest. One of the goals of the NIJ 07 testing is to reduce the chance of a bullet skipping off of areas where the armor has curves, which is of particular concern for female officers. LaGanke believes Kevlar Exo can help solve this ricochet problem, which can affect both male and female officers.

“Everybody has a different body shape, so the ricochet issue is not just about female officers,” he explains. “We did a focus group with six different officers, including two female officers, and everybody had a different opinion about their current armor. But one thing they all really liked about [armor made from Kevlar Exo] is how it conformed to their bodies.” Bullets are less likely to ricochet off of softer, stronger material that conforms better to the body, according to LaGanke.

Another officer safety benefit to Kevlar Exo’s flexibility is that it makes armor easier to wear when running, jumping, and fighting. “If you’re trying to get into a situation or get out of a situation, trying to get behind cover, or just getting out of your patrol car, you’ll be more agile with Kevlar Exo. When you move, it moves with you,” LaGanke says.

Point Blank Enterprises has a multi-year exclusivity contract with DuPont for using Kevlar Exo to produce body armor for North American state and local law enforcement, LaGanke says. Other manufacturers can use the material to produce armor for federal agencies and for wearers outside of law enforcement.

Point Blank’s first soft body armor for law enforcement featuring Kevlar Exo was being evaluated under the NIJ’s 06 standard at presstime. LaGanke says he thinks the product will be added to the NIJ’s Compliant Products List and available for agency purchase by the end of the fall. At presstime independent labs were still prepping to evaluate body armor by the NIJ 07 standard. They are expected to be ready to do so in 2025.

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