Body Armour Market Size and Share Outlook - Forecast Trends and Growth Analysis Report (2025-2034)

The global body armour market reached a value of nearly USD 3.03 Billionin 2024. The market is assessed to grow at a CAGR of 5.00% during the forecast period of 2025-2034 to attain a value of around USD 4.94 Billion by 2034 . The market is being driven by growing military spending, increasing use of body armour in non-military sectors, the development of smart and technologically advanced body armour systems, advancements in material sciences, and the growing trend of sustainability.

Global Body Armour Market Growth

Countries globally are increasing their defence budgets and modernising defence forces amid growing security threats, surging the demand for personal protective equipment (PPE), including body armour. In 2023, the US military spent nearly USD 820.3 billion, representing 13.3% of the country’s federal budget.

Factors such as growing geopolitical tensions, the increasing number of counterterrorism initiatives, and surging crime rates are driving the body armour market development. Rising incidences of violent crimes, especially in urban areas, are raising safety concerns, boosting the demand for civilian body armour.

North America accounts for a significant share of the market amid an increasing number of programmes initiated by the US government such as the Soldier Protection System-Torso and Extremity Protection (SPS-TEP) to provide full body armour to armed forces and higher expenditure on the military sector.

There is an increasing demand for smart technologies, including GPS trackers, communication systems, hydration packs, and medical sensors, among others, in body armour systems to improve operational efficiency and situational awareness.

Key Trends and Recent Developments

Increasing demand for lightweight body armour; advancements in material science and 3D printing; and surging focus on sustainability are favouring the body armour market expansion.

November 2023

Integris Composites launched Rapid Don/Doff body armour vests for law enforcement and military units. The new armour reduces the time for donning and doffing one's body armour rig—by 50% or more.

October 2023

Dyneema®, owned by Avient Corporation, announced the launch of a next-generation unidirectional (UD) material innovation to improve the mobility and safety of law enforcement officers and military forces. The new material, with improved ballistic stopping power, enables body armour manufacturers to design soft armour vests 10–20% lighter than previous protective solutions.

April 2023

DuPont unveiled Kevlar® EXO™ aramid fibre, enabling the development of body armour that provides excellent ballistic protection to law enforcement and military officers without compromising on mobility and comfort. Kevlar® EXO™ contours to body lines and curves, offering a body-inclusive solution while providing maximum protection.

April 2022

MKU, along with the Armed Forces of the Philippines, announced the launch of first-of-its-kind body armour systems that are modular and mission-configurable to enhance the on-field efficiency of soldiers. The systems comprise the Insta Load Distribution System (ILDS), an integrated rucksack, a laser cut molle system, a quick release system, and a hydration pack. The armour is aimed at supporting soldiers to reduce fatigue and retain energy while enabling them to carry out missions with enhanced mobility, comfort, endurance, and survivability.

Growing demand for lightweight body armour

There is a growing demand for lightweight body armour that enables wearers to increase speed, mobility, and endurance while reducing fatigue. Manufacturers are increasingly investing in advanced materials like Dyneema, Kevlar, ultra-high-molecular-weight polyethylene (UHMWPE), and graphene to develop lightweight body armour with enhanced protection and comfort.

Advancements in material sciences

Advancements in material sciences are leading to the development of lightweight materials that offer better protection and ballistic performance than traditional materials for use in body armour solutions. Increasing research in multi-functional materials is expected to drive the creation of body armour that protects wearers from ballistic threats as well as blunt force trauma, knife stabs, and explosions.

Increasing use of 3D printing

Key players are increasingly leveraging 3D printing technology to create body armour systems that are made with lightweight structures and advanced composites and conform to an individual’s body shape for improved mobility and comfort and enhanced coverage accuracy. Additive manufacturing also supports the development of modular armour systems, enabling users to interchange panels and integrate accessories as per their requirements.

Growing focus on sustainability

The growing focus on sustainability is driving the body armour market development. Manufacturers are shifting towards recycled fibres, bio-based polymers, and natural fibres that can reduce the environmental impact of production while enhancing the mobility and comfort of wearers. They are also adopting energy-efficient manufacturing processes and utilising renewable energy sources to optimise manufacturing workflow and reduce carbon emissions.

Global Body Armour Market Trends

There is a growing deployment of 3D printing to upgrade existing body armour systems, extending their performance and lifecycle. Nanomaterials, due to their low weight and excellent strength, are increasingly used as raw materials in 3D printing body armour systems with improved impact protection and excellent resistance to cracking and scratching. Moreover, the rising focus on sustainability is boosting the applications of 3D printing to create materials with little to no waste, hence reducing the quantity of raw material waste.

Key players in the body armour market are attempting to develop self-healing materials for maintaining the integrity of body armour and lowering incidences of failure after an impact. Advancements in material technologies are expected to drive the development of customised body armour that can be tailored in accordance with the specific needs of a wearer.

Global Body Armour Industry Segmentation

The EMR’s report titled “Global Body Armour Market Report and Forecast 2025-2034” offers a detailed analysis of the market based on the following segments:

Market Breakup by Product

• Soft Armour
• Hard Armour
• Accessories

Market Breakup by Level

• Level I
• Level IIA
• Level II
• Level IIIA
• Level III
• Level IV

Market Breakup by Material

• Steel
• Ultra-high-molecular-weight polyethylene (UHMWPE)
• Aramid
• Composite ceramic
• Others

Market Breakup by Application

• Defence
• Law enforcement protection
• Civilians
• Others

Market Breakup by Region

• North America
• Europe
• Asia Pacific
• Latin America
• Middle East and Africa

Global Body Armour Market Share

As per the body armour market analysis, soft body armour accounts for a significant share of the market as it is made from flexible materials that can conform to the wearer’s body shape. Soft body armour is lightweight, concealable, and comfortable; hence it is typically used by military personnel and law enforcement officers who must remain agile in high-pressure situations.

Hard body armour, made from ceramic, steel, or polyethylene, offers enhanced protection against high-powered ammunition and rifle threats. It is typically used by military personnel in high-risk environments, specialised law enforcement units facing high-risk situations, and private security companies working in dangerous environments. Meanwhile, body armour accessories such as helmets and carrier systems are designed to enhance the versatility, comfort, and functionality of body armour systems.

Competitive Landscape

Key body armour market players are actively investing in research and development (R&D) activities to create stronger, lighter, and more flexible materials. They are also exploring the use of recyclable and bio-based solutions to lower the environmental impact of their products. Besides, body armour companies, by utilising technologies like 3D printing, are attempting to develop personalised and customised solutions.

Kejo Limited Company

Kejo Limited Company, established in 1997 and headquartered in Florida, United States, is a key supplier of body armour to the US Navy, US Army, Marines, and the US Air Force. Its KEJO™ Saviour ™ EOD Bomb Suit is designed to provide maximum protection with minimum weight, making it one of the world’s most advanced high-performance affordable suits.

BAE Systems plc.

BAE Systems plc., headquartered in London, United Kingdom, and founded in 1999, is one of the world’s biggest aerospace and defence companies. It offers innovative technologies to empower businesses to detect and defend against the latest cyber and physical threats and deliver advanced technologies.

Armored Republic LLC

Armored Republic LLC, headquartered in Arizona, United States, and established in 2012, is a prominent manufacturer of body armour solutions designed for rifle and pistol threat protection. The company develops innovative new products and affordable body armour and ballistic systems.

Craig International Ballistics Pty Ltd.

Craig International Ballistics Pty Ltd., founded in the late 1990s and headquartered in Australia, is a leading manufacturer of combat-proven armour systems. The company has supplied over 350,000 soft armour inserts, training products, and hard ballistic plates to the ADF.

Other key players in the body armour market include Pacific Safety Products Inc., and Ballistic Body Armour (Pty) Ltd, among others.
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