DuPont and Hohenstein develop new tests to measure comfort and mobility in body armor

DuPont has introduced three new testing methods designed to evaluate how comfortable and flexible soft ballistic body armor feels in real-world use. Created with German research institute Hohenstein, the protocols aim to help manufacturers design armor that protects without limiting movement or causing fatigue.

For years, police officers have reported removing their vests during long shifts due to discomfort. Stiff or restrictive armor not only causes fatigue but can also slow reaction times and raise the risk of injury. DuPont’s new tests are meant to address these issues by focusing on how armor behaves during realistic body movements.

Christophe Djololian, Global Market Development Leader at DuPont, said the company’s goal is to better understand how armor feels from the wearer’s point of view. “By taking into account body movement and specific end-use scenarios, we can more accurately evaluate discomfort and mobility constraints,” he explained.

The three new tests are:

• Lower Costal Bending (LCB) Test – Measures how armor responds to upper body bending motions and how much energy is lost due to stiffness.
• Double Curvature Compression (DCC) Test – Simulates a bent torso to assess how well materials conform to complex body shapes, helping ensure better freedom of movement.
• Edge Pressure (EP) Test – Identifies pressure points at vest edges such as the neck, arms, and lower abdomen, where discomfort is most common.

Dr. Jan Beringer, Senior Scientific Expert at Hohenstein, said the methods were built around real wear trials. “It’s in our DNA to get as close as possible to the user’s reality,” he noted. “We analyzed discomfort and motion restrictions through testing, then designed simulations to reflect that experience.”

Steven LaGanke, DuPont’s Global Segment Leader, emphasized that comfort and protection should go together. “With these new test protocols, we can now quantify flexibility in body armor. As we design new materials like Kevlar® EXO™ fabrics, this helps create more balanced solutions for those who rely on their gear every day.”

The collaboration marks a step toward standardizing how comfort is measured in protective wear, giving law enforcement and military personnel body armor that performs better under pressure—and feels better to wear.