- The advent of plastics allowed for the invention of ballistic protection. Bulletproof vests, more appropriately known as bullet resistant vests, were first developed in the 1940s, but it is only since the 1970s, with the invention of Kevlar, that they came to be produced much in the same way that they are today. Bulletproof vests are simply many layers of Kevlar, or similar material, sewn together to form protection against firearms. While basic in concept, quite a lot goes into the manufacturing of the bulletproof vest.
- A complex form of plastic, Kevlar requires a great deal of laboratory work just to build the raw material for a bulletproof vest. The complex polymer, called Kevlar commercially, is more appropriately named para-phenylenediamine. Producing para-phenylenediamine typically results in long, crystallized rods, which are then run through a metal plate stamped with holes. The final product, after being hardened and wound on on spools, is Kevlar fiber. This fiber is then woven, in the most simple way possible, to produce Kevlar cloth.
- Once the Kevlar fiber has been woven into cloth, it is shipped to the bulletproof vest maker. Large vest shapes are cut out and layered on top of each other. Vests contain between eight and 25 layers of Kevlar. The various layers are sewn together by hand or machine, using standard sewing practices.
- While the bullet resistant qualities of the final vest are already in place, a few concessions are made to style and comfort. Typically the Kevlar layers are inserted into a polyester or cotton shell. In many vests, the shell contains additional pockets that can accommodate further layers of shielding, such as nylon padding or ballistic ceramics.
