How its made: Bulletproof Vests
As you may know, not all bulletproof vests are the same. Some of the main types of vests around today are made with polyethylene or kevlar. Both have their advantages and disadvantages.
First, you start with a fabric shape that you want to accomplish. Let's say you want something like this.
You'll start with having a fabric company outline the measurements and sizes that you will need. Frankly I'm not a fabrics and sewing company so I can't get too into that. However we do have to make room for an insert to be put into the vest.
Once we've decided on the size and shape the new vest will be we then take those measurements and begin making an insert that can be removed if the user needs to wash the outside of the vest.
This insert is commonly made from kevlar or polyethylene and not metals. This is simply because of how heavy and rigid metals can be. However, polyethylene or kevlar aren't exactly the softest and most moveable things in the world.
Once made, the compacted insert is then wrapped and sewed into another fabric to hold it together and protect it from minor spills and damage.
From there it is simply a matter of putting the two pieces together, testing the vest, and then making a few more prototypes before testing again.
Assuming everything tests well and there seems to be a demand for that vest style we then begin full production in our factory!