UHMWPE vs Kevlar: Strength, Durability, and Weight

Body armor has evolved significantly over time. In our article level 3+ ceramic plates we talked about the history of hard body armor and its evolution. In this article, we will be talking about two common materials used in soft body armor, UHMWPE vs Kevlar. This article is of particular importance to me coming from a family who served their county and community in the military and law enforcement.

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UHMWPE (Ultra-High Molecular Weight Polyethylene) and Kevlar are two materials widely used in the manufacturing of body armor. In this article, we will delve into the key differences and similarities between UHMWPE and Kevlar body armor, to help you see the evolution of soft body armor.

Armor Overview

UHMWPE Body Armor

UHMWPE is a long-chain thermoplastic known for its remarkable strength, durability, and lightweight properties. These characteristics make it an attractive choice for body armor. UHMWPE fibers are woven into sheets and then layered to create ballistic panels, which can be used in various types of body armor including bulletproof vests and helmets.

Kevlar Body Armor

Kevlar is a para-aramid synthetic fiber also renowned for its high strength-to-weight ratio and durability. It was invented in by chemist Stephanie Kwolek. The fibers found their way to replacing steel parts on tires, used in canoes, and all types of products. Kevlar fibers are woven into a fabric, which is then layered and used to produce ballistic panels for body armor applications. The precursor to UHMWPE, Kevlar is utilized in bulletproof vests, helmets, and other protective gear.

Ballistic Performance

Both UHMWPE and Kevlar offer excellent ballistic performance. However, UHMWPE exhibits a higher tensile strength, which translates to superior energy absorption capabilities. Consequently, UHMWPE body armor tends to be more effective at stopping bullets and reducing blunt force trauma. Kevlar, while still providing strong ballistic protection, does not perform as well as UHMWPE under similar circumstances. Ultimately, Kevlar paved the way for UHMWPE and is now an obsolescent design, but that doesn&#;t mean it&#;s bad. Kevlar was the peak of performance back in the day, and was used in law enforcement vests, flak jackets, and helmets. Kevlar led to the ultimate functional design of UHMWPE. 

Weight

Weight is a factor when considering body armor as it directly impacts the wearer&#;s mobility and comfort. Let&#;s be honest, if body armor is too uncomfortable who would wear it? UHMWPE body armor comes in at a lower weight than Kevlar due to the material&#;s inherently low density. This reduced weight not only enhances wearer comfort but also allows for improved maneuverability. This makes UHMWPE armor a good choice for those who require extended periods of wear.

Durability and Environmental Resistance

Both UHMWPE and Kevlar body armor demonstrate impressive durability and resistance to environmental factors. However, UHMWPE offers better resistance to moisture, UV radiation, and chemicals, which can be significant in maintaining the armor&#;s performance over time. Kevlar is more susceptible to degradation when exposed to certain chemicals and UV radiation, which may necessitate more frequent replacement or additional protective measures. That said, most armor manufacturers recommend replacing soft body armor every five years, more often if it is worn every day, due to the interaction with body fluids and oils. 

Flexibility and Comfort

UHMWPE fibers are more flexible than Kevlar fibers, which can impact the overall comfort of the body armor. The increased flexibility of UHMWPE allows for greater freedom of movement and a more comfortable fit. Kevlar tends to be a bit more rigid and needs more form fitting. 

When it comes to UHMWPE vs Kevlar, they are both high-performance materials used in body armor, with unique strengths and characteristics. However, they are both an example of the evolution of body armor. Kevlar used to be the premiere option for soft armor. UHMWPE is now considered to be and is also used in the production of many hard armor plates. It is likely as armor advances there will be a new contender that will knock UHMWPE off its throne.

The opinions expressed in this post are those of the author and do not necessarily reflect the views and opinions of Tacticon Armament.

Kevlar and UHMWPE (Ultra-High Molecular Weight Polyethylene) are both high-performance synthetic fibers widely recognized for their exceptional strength-to-weight ratios and amazing resistance to impact and abrasion. While they share a lot of similarities, there are distinct differences between the two materials that you&#;ll need to know in order to pick the right one for what you want in your riding gear.

Are you interested in learning more about UHMWPE Fiber? Contact us today to secure an expert consultation!

Closeup of Kevlar material

What is Kevlar?

Kevlar, developed by DuPont in the s, is an aramid fiber renowned for its extraordinary strength. It is composed of long-chain polymers with rigid molecular structures that provide an incredible amount of tensile strength. Kevlar is often used for its resistance to high temperatures, as in bulletproof vests, helmets, and body armor for motorcycle riders as well as military and law enforcement. Kevlar is also used in the aerospace and automotive industries because of its invaluable strength and heat resistance.

Closeup of UHMWPE material, image from namilong.com

What is UHMWPE?

UHMWPE is a high-strength, lightweight polyethylene fiber that is also extremely durable and impact resistant. It was first introduced commercially in the s and has since gained a ton of popularity for its strength and flexibility. UHMWPE is created by aligning the polymer chains during a gel-spinning process that results in a material with high tensile strength. Like Kevlar, it&#;s used in the manufacture of bulletproof vests, protective gloves, but is also used in making ropes and sails because of its strength, light weight, and resistance to chemicals and UV radiation.

Pando Moto UHM Mesh Riding Jacket

Wear alone as a mesh summer riding jacket or as an armored base layer below any other apparel of your choosing. This zip-up is made of extremely durable power-stretch UHMWPE material, which is 15 times STRONGER than STEEL, in the most vulnerable areas.

What&#;s the Difference?

One of the main differences between Kevlar and UHMWPE is their molecular structures. Kevlar has a more rigid and crystalline structure, making it highly resistant to penetration and cutting forces. It is fantastic at absorbing and distributing impact energy, making it ideal for situations that would require protection against ballistic threats. UHMWPE has a more flexible and elongated molecular structure, meaning it has incredible impact resistance and the ability to dissipate energy very effectively. It is particularly useful for situations that would require flexibility and protection against sharp objects, such as cut-resistant gloves or knife-proof vests.

Another important distinguishing factor is their density. Kevlar has a higher density compared to UHMWPE, resulting in slightly heavier finished products. UHMWPE might be appealing for motorcyclists to reduce the bulk that Kevlar-lined gear may add. While this might be important in some other very specific situations where weight is a key factor, the difference in density is generally negligible for most uses.

In addition, UHMWPE is waterproof and won&#;t be weighed down by liquid absorption. This makes UHMWPE ideal for use in tents and backpacks which may be used in wet or humid conditions. On the other hand, Kevlar can absorb up to 3.5% of its own weight in water! A UHMWPE jacket would remain comfortable for longer in hot and humid weather for motorcycle riders and would provide some water resistance if there's unexpected rain.

Ultraviolet light resistance is also an essential factor in the lifespan of heavy-duty fibers that spend a lot of time outside or in the sun. Kevlar will lose up to 25% of its material strength after two days of UV exposure, while UHMWPE loses only up to 5%. This is an important distinction for manufacturing products that are used outdoors.

Kevlar and UHMWPE also have different thermal properties. Kevlar can withstand higher temperatures without significant degradation, which means that it maintains its strength and integrity even in extremely hot conditions. For this reason it is perfect for flame-resistant clothing or protective equipment for firefighters. UHMWPE has a lower melting point and may deform or lose strength at higher temperatures. However, UHMWPE is a less popular choice to be worn in cooler temperatures because it does not have as impressive insulation capabilities as Kevlar.

In terms of cost, Kevlar is generally more expensive than UHMWPE. The production process and the raw materials involved contribute to its higher price point. UHMWPE is often chosen for situations when cost is most important without compromising on strength and durability.

Both Kevlar and UHMWPE are amazing materials that have changed the world and have made many industries and activities safer&#; especially within the world of motorcycles. Both offer protection from different kinds of threats, but knowing their key distinctions is important for choosing which will function best for your needs. The Pando Moto Commando Mesh UHM Jacket uses UHMWPE instead of Kevlar and claims to be 15x stronger than steel! In terms of comfort and wearability in comparison to the Kevlar-lined Sherpa Trucker Jacket, we&#;ll let you be the judge!

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