A plate’s lay-up, its materials and the threat it is tested against: these decide what armor is worth in the field.
01 — Cutaway · plate architectures
Three hard-plate architectures: monolithic UHMWPE, the ceramic + PE hybrid and, for comparison, steel. Architecture, meaning strike-face hardness and backer toughness, matters more than thickness.
01 / 03KG product
Monolithic polyethylene · stand-alone
| Test threat | 7.62×51 M80 Ball |
|---|---|
| Weight · SAPI | 1.5–1.9 kg |
| Buoyancy | Yes |
| AP protection | Limited |
| Multi-hit | High |
| Temperature sensitivity | Sensitive above 70 °C |
| Cost | Medium |
| Best suited for | Naval and air operations, special missions |
Layers
02 / 03KG product
Al2O3 / SiC strike face + UHMWPE backer
| Test threat | .30-06 M2 AP |
|---|---|
| Weight · SAPI M | 2.7–3.1 kg |
| Buoyancy | No |
| AP protection | Full (.30-06 AP) |
| Multi-hit | Limited (ceramic fractures) |
| Temperature sensitivity | Low sensitivity |
| Cost | High |
| Best suited for | Land combat units, high threat |
Layers
03 / 03Reference architecture
Reference architecture for comparison
| Test threat | 7.62×51 M80 Ball |
|---|---|
| Weight · SAPI M | 3.5–4.0 kg |
| Buoyancy | No (sinks) |
| AP protection | No |
| Multi-hit | Spall / ricochet risk |
| Temperature sensitivity | No sensitivity |
| Cost | Low |
| Best suited for | Firing ranges, static protection, tight budgets |
Layers
Reference architecture for comparison — not part of the KG catalogue.
Steel throws fragments and ricochets as it deflects a round, which is why it is used with an anti-spall coating.
Gold mark: protection level stated in the KG product data sheet
02 — Materials science
Modern ballistic armor is never a single material: high-strength fibres and technical ceramics, each strongest against a different type of threat, work together.
Ultra-high-molecular-weight polyethylene
A fiber lighter than water with very high tensile strength for its weight. Bullet energy travels along the fibers and spreads over a wide area.
| Density | 0.97 g/cm³floats |
|---|---|
| Tenacity | 3.0–4.0 N/tex |
| Crystallinity | > 95 % |
| Architecture | UD prepreg · 0°/90° |
| Use | Naval and air platforms, weight-critical armoring |
Para-aramid synthetic fiber
The standard for soft ballistic packs thanks to its high tensile strength. Not to be confused with meta-aramid, which is used for heat resistance.
| Tensile strength | ~3.6 GPa |
|---|---|
| Areal density | 400–600 g/m² |
| Weave | Plain · basket · 2×2 satin |
| Plies | 20–40 per pack |
| Use | Soft armor panels, ballistic helmet shells |
Al2O3 · SiC · B4C
The plate’s strike face: it breaks up the armor-piercing projectile first, then the backer spreads the energy. Ceramic is never armor on its own; it is always part of a composite system.
| Al2O3 | 3.7–3.9 g/cm³economical |
|---|---|
| SiC | 3.2 g/cm³strong against AP |
| B4C | 2.5 g/cm³lightest, hardest |
| Architecture | Monolithic or mosaic/hex |
| Use | NIJ III / IV hard plates, armor-piercing threats |
Schematic texture — not a micrograph.
From material to system
Ceramic is never armor on its own; it is always part of a composite system.
03 — Threat rule · NIJ 0101.06
NIJ 0101.06 is a widely used reference edition for personal body armor (the newer 0101.07 names its levels differently). The rule shows one reference round per level; IIA–IIIA each specify two rounds. Choose a level: the reference round, its energy and the KG products rated at that level update together.
Energy rule · NIJ 0101.06 · 0–4,500 J
9mm FMJ RN
NIJ IIA · Handgun — light
No product in the catalogue is rated at this level. If you need protection at this level, we can review it as a special project.
Special project enquiryA product protects to the level and test round stated in its data sheet. Do not accept a product without a stated level; ask for the test report with the quote.
.357 Magnum JSP
NIJ II · Handgun — standard
A product protects to the level and test round stated in its data sheet. Do not accept a product without a stated level; ask for the test report with the quote.
.44 Magnum SJHP
NIJ IIIA · Handgun — heavy
Wrong“Aramid stops everything.”
CorrectAramid is a soft ballistic material; it does not stop rifle rounds (especially armor-piercing) on its own. Rifle threats need a hard plate.
7.62×51 NATO M80
NIJ III · Rifle — NATO ball
Wrong“NIJ III+ is an official level.”
Correct“III+” is a manufacturer’s marketing label; it does not exist in the NIJ standard. Ask for the test round and the V50 velocity.
.30-06 M2 AP
NIJ IV · Rifle — armor-piercing
Wrong“NIJ IV automatically covers III.”
CorrectThe NIJ IV test is a single .30-06 M2 AP shot. Multi-hit M80 performance must be verified separately.
| Level | Class | Test round | Mass (g) | Mass (gr) | Velocity (m/s) | Energy (J) | Typical use | Rated KG products |
|---|---|---|---|---|---|---|---|---|
| NIJ IIA | Handgun — light | 9mm FMJ RN | 8.0 | 124 | 373 | 557 | Covert patrol | None in the catalogue — special project |
| NIJ II | Handgun — standard | .357 Magnum JSP | 10.2 | 158 | 436 | 969 | Law enforcement | |
| NIJ IIIA | Handgun — heavy | .44 Magnum SJHP | 15.6 | 240 | 436 | 1,482 | Soft armor, helmets | |
| NIJ III | Rifle — NATO ball | 7.62×51 NATO M80 | 9.6 | 147 | 847 | 3,444 | Hard plate (stand-alone) | |
| NIJ IV | Rifle — armor-piercing | .30-06 M2 AP | 10.8 | 166 | 878 | 4,151 | Ceramic + PE hybrid plate |
Gold mark — on the rule: the test energy the standard defines for the selected level’s reference round; next to products: the protection level stated in the KG product data sheet.
04 — Coverage matrix
Each architecture is covered only at its rated level. A higher rating does not automatically document lower threats; lower levels must be confirmed by a test report.
| NIJ level | Soft panel — Ballistic Vest product page NIJ IIIA · aramid | UHMWPE plate — compare in the cutaway NIJ III | Ceramic + PE — compare in the cutaway NIJ IV | Steel — compare in the cutaway NIJ III · reference |
|---|---|---|---|---|
| IIA — show on the rule 9mm FMJ RN | Lower levelconfirm by report | Lower levelconfirm by report | Lower levelconfirm by report | Lower levelconfirm by report |
| II — show on the rule .357 Magnum JSP | Lower levelconfirm by report | Lower levelconfirm by report | Lower levelconfirm by report | Lower levelconfirm by report |
| IIIA — show on the rule .44 Magnum SJHP | Coveredrated level | Lower levelconfirm by report | Lower levelconfirm by report | Lower levelconfirm by report |
| III — show on the rule 7.62×51 NATO M80 | Not covered | Coveredrated level | Lower levelconfirm by report | Coveredrated level |
| IV — show on the rule .30-06 M2 AP | Not covered | Not covered | Coveredrated level | Not covered |
05 — Errata
What buyers of body armor are often told — and what is actually true.
Wrong“Aramid stops everything.”
CorrectAramid is a soft ballistic material; it does not stop rifle rounds (especially armor-piercing) on its own. Rifle threats need a hard plate.
Wrong“NIJ III+ is an official level.”
Correct“III+” is a manufacturer’s marketing label; it does not exist in the NIJ standard. Ask for the test round and the V50 velocity.
Wrong“Thicker means better protection.”
CorrectArchitecture (strike-face hardness + backer toughness) matters more than thickness. The wrong lay-up cannot spread the energy.
Wrong“Armor lasts forever.”
CorrectManufacturer warranties are usually time-limited. Soft armor is sensitive to moisture and sweat; UHMWPE loses performance if stored above 70 °C for long periods.
Wrong“Steel plates are the safest.”
CorrectSpall/ricochet risk and weight are serious drawbacks versus composites: a steel NIJ III plate weighs 3.5–4.0 kg, its UHMWPE equivalent 1.5–1.9 kg.
Wrong“NIJ IV automatically covers III.”
CorrectThe NIJ IV test is a single .30-06 M2 AP shot. Multi-hit M80 performance must be verified separately.
06 — Platform standards
Beyond personal armor, vehicle, naval and aircraft armoring, as well as glazing, doors and visors, follow their own standards.
NATO’s protection levels for vehicle occupants. Only the kinetic threat steps are shown here.
The level is set per project.
Model families for land, naval and air platforms. The final level and weight are set per project.
No equivalence tables are given; a product’s level is stated in the quote and the test report.
Ballistic glazing (BR1–BR7)
European standard that defines the bullet-resistance classes of security glazing and their test method.
Related productsBallistic Glass
Ballistic doors, windows, panels
Classifies the bullet resistance of doors and windows (EN 1522) and sets the test method (EN 1523).
Related productsBallistic Door
Vehicle and visor protection levels
Guidelines of the Germany-based association of test institutes, used as the reference for vehicle and visor protection levels.
Related productsVehicle ArmoringBallistic Visor
NIJ 0101.07 names its levels differently. The quote states which edition of the standard each product was tested to.
07 — Documents
Product data sheets and test reports are shared on request. Add the standard documents you need to your request list; they will be waiting in the quote form.
Reference standards
Contact
Share your threat level, weight target and use case; our engineering team will work out the right configuration with you.
