Which Plate Carrier Should I Get?

A common question that we receive when asked about our plate carriers is: Which plate carrier is the best?

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Before you start your carrier search, consider some of the following questions to help determine what type of plate carrier you need:

• Protection: Do you want a concealable carrier for soft armor or an external carrier for rifle-rated plates?
• Modularity: How much real estate and modularity do you need for tool and gear storage (magazine pouches, medic kit, etc) on your carrier?
• Price: What is your budget?

Taking the time to answer these questions should help you narrow down your best option. Keep in mind a plate carrier is just a catalyst to hold armor against your body and is just a piece of fabric with no armor in it. This means aside from a few key features like a cummerbund, buckle and quick release functions, plate size compatibility, and padding - aesthetics will ultimately play a factor in your decision. There may be 4 or 5 different carriers that all provide the same features but look slightly different. 

We stand by all our carrier models as well-crafted and durable. But what are some of the differences between each model? Let&#;s start off with our simplest and one of our lightest carriers as we give you a description of each one.

AR Concealment

The Concealment Carrier is one of our lightest and lowest-profile carriers at 0.54 - 0.6 lbs depending on what size you get. It's an excellent choice if you need a discreet carrier for soft armor to protect against common handgun threats. 

Features:

• It&#;s easy to wear under your clothing to protect against 95% of ammunition used in shootings.
• Gives you a snug, comfortable fit from the thin, cummerbund wrapping.
• Made from a moisture-wicking, breathable tactical polyester fabric blend.
• Designed to move with your body without chafing.
• The Medium size will fit body types M to XXL, and the Large will fit up to 3XL.

Note: The Concealment Carrier is only for use with soft armor. If you're interested in a lightweight, minimalist setup for hard armor, you should check out the Invictus. 

AR Invictus

Latin for Undefeated, the Invictus is a minimalist, but rugged model. It fits 10&#;x12&#; plates while weighing in at only 1.3 lbs. This is our lowest-profile hard armor carrier. 

Features:

• Low profile Hypalon shoulder straps allow the overlay of a rucksack or 3-day assault packs 
• The thin profile of the plate pocket allows you to get as low as possible to the ground when needing to prone out 
• Nylon laminate cummerbund with elastic anchor points allow the cummerbund to flex when you breathe 
• Side plate pocket accommodation gives you the option of more coverage.
• Laser-cut molle webbing keeps the PALS/MOLLE interface as low profile as possible, further aiding in reducing your overall profile for vehicle and doorway egress.
• For sizes ranging from M to XXL.
• Features a reinforced &#;fist pack&#; drag handle with a 3D texture - making it easier to grip someone and drag them out of the fray.
• Compatible with aftermarket Pontoon Pads for cooling.  
• Made out of 500D Cordura: a load-bearing and IR reducing material.

What if you don&#;t need a carrier for large plates? We&#;ve got that covered, too in our AR Freeman Carrier. 

AR Freeman

The AR Freeman is a minimalistic approach for anyone who does not want or need a large plate carrier. It's compact enough to fit in your daypack or under your vehicle seat. Yet this carrier can still fit 3 magazine pouches via the PALS channels. We designed this carrier to be no-frills and offer everything you need with nothing you don't to help keep size and cost to a minimum

Features:

• Compact carrier and plates, intended for operators below 5&#;4&#; or anyone needing a compact and affordable set of armor.
• Low profile Hypalon® shoulder straps allow the interface of rucksacks and 3-day assault packs.
• Laser-cut PALS system to accommodate up to three magazine pouches or other MOLLE-compatible accessories.
• For sizes ranging from S to XL.
• Quick on/off with the rugged, impact-resistant side buckles 
• Made out of 500 D Cordura, a load-bearing and IR-reducing material.

Note: The AR Freeman carrier is specifically designed to work with our proprietary 9&#;x9&#; armor and is sold as a complete setup.

Testudo

Named after the Roman army&#;s impenetrable formation, the Testudo is our flagship plate carrier. We designed it with maximum coverage in mind, right out of the box.

It is considered the everyman's carrier: everything you need with nothing you don't. It has an under-buckle system that will allow you to use it without a cummerbund, similar to the Veritas, or with the buckle system removed for a low profile and comfortable cummerbund interface. The testudo is the only carrier we provide that also has the ability for side plate usage with no additional side plate pouch. Lastly, keep in mind the Testudo will house either 10&#;x12&#; -or- 11&#;x14&#; main plates

Features:

• A fully-adjustable cummerbund provides a tight fit and optimal mobility.
• A generous amount of PALS webbing gives you plenty of space for attaching magazines, medical kits, and other accessories. All PALS webbing has the addition of Loop material for the additional compatibility with hook pouches and morale patches. 
• Internal Admin and Kangaroo pockets allow for the storage of small gear and kangaroo insert dividers for a triple magazine pouch conversion.
• 3D mesh foam spacer padding creates an excellent layer of breathability between you and the carrier
• The shoulder buckle system when combined with the side buckle set-up allows for super quick donning and doffing
• With the side buckle system removed, the carrier is set up for all-day comfort such as needed on an 8-hour foot patrol. 
• Side plate pockets give you extra coverage with plate sizes 6&#;x8&#; and smaller.
• For sizes ranging from M to 3XL. Note that the cummerbund uses a lace and shock cord system that can be modified with a longer or shorter piece of cord to increase or decrease size outside of the standard range. 
• Made out of 500D Cordura material which is a load-bearing and IR-reducing material.

Interested in the Testudo, but want something slightly more minimal or more affordable? Check out the Testudo&#;s little brother, the Veritas.

Valkyrie

The Valkyrie is our top-of-the-line, military-grade carrier. This is for military, law enforcement, or anyone interested in such a high-quality carrier at a reasonable price.

Features:

• The Valkyrie is Berry compliant, meaning it is 100% designed, sourced, and manufactured in the USA.
• Has a removable side buckle system under the cummerbund so the carrier can be used as a quick don/doff type or can be used with just the cummerbund for low profile all-day comfort. 
• Cummerbund is compatible with our Side Plate Pouch system and has a layer of mesh for additional venting. 
• Plate pocket thickness is compatible with all ESAPI and composite armor-type plates.
• Compatible with all chest rigs, MOLLE style pouches and gear, and Placards. 
• Low profile Drag handle can be secured to the rear plate bag when not in use.
• Internal Admin and Kangaroo pockets on the front plate pocket for storage of small gear and the addition of our Kangaroo Magazine Insert to divide the space up into a triple mag pouch.
• Quick Detach buckles are located in the front of the shoulder strap for maximum comfort. 
• Made out of 500D Cordura which results in load-bearing and IR-reducing material.
• For sizes ranging from M to XXL.

Conclusion

In summary, you must pick the carrier that works best for your needs. You can&#;t always just go off of reviews, because what&#;s right for someone else might not be right for you. Once you have narrowed down what main features you are looking for aesthetics will have a lot to do with your selection. The main features you always want to assess from top to bottom will be: 

• Shoulder Strap Style or Shoulder Pad
• Plate Pocket Size
• Padding
• Carrier Profile 
• Cummerbund or Side Buckle System
• Carrier Material
• Carrier Color 

We hope this guide has helped you figure out which carrier is right for you. As always, please contact us with any questions and we recommend finding a good trainer in your area who can train you on firearm and body armor integration and usage. 

View All Armored Republic Plate Carriers.

Today we will be covering what is possibly the most common body armor in civilian circulation. Steel body armor, particularly AR500 is one of the most affordable body armor options available generally costing between $75-150 per plate. Reputable manufacturers like Tacticon use ballistic grade steel to make body armor, this ensures that the steel is always at least AR500 on the Brinell hardness scale, which we will cover more in depth later. This is important as ballistic steel has much more stringent quality control processes than your average steel sheets. AR500 armor is rated NIJ level III, it is designed to address 7.62×51, as with every armor there are benefits and tradeoffs, let&#;s get started.  

Main differences between AR500, AR550, and AR600

The differences between AR500, AR550, and AR600 armor have everything to do with the hardness of the steel. The harder the steel the lighter and thinner the plate can be made, and the greater ballistic protection. As hardness increases so does brittleness, but that won&#;t really come into play for these purposes until you get above AR. Steel armor plates are all part of the Level III body armor category and are designed to protect the wearer from rifle fire.

However, there are differences between these three types of plates, namely in their hardness level, weight, thickness, and the specific ballistics they can stop. 

AR500 Steel Body Armor Plates 

The AR500 steel plates have the lowest hardness when it comes to steel plates, but still offer solid protection. Specifically, AR500 plates are designed to protect against rifle calibers ranging from 9mm through .308 at speeds of up to 2,780 feet per second.

AR500 plates are typically 1/4-inch thick, without a fragmentation coating, providing a good balance between protection and mobility. However, they are the heaviest among the AR series, something to consider for wearers who need to maintain a high level of mobility.

AR550 Steel Body Armor Plates

 A step up from AR500, AR550 steel plates offer increased hardness and protection levels. They are lighter, and being harder than AR500, offer slightly more protection against different threats. 

AR550 plates are generally slightly thinner than AR500 plates, leading to a greater level of durability and resistance to bullet impacts. As with the AR500, the decreased thickness and increased hardness do contribute to a lighter-weight plate.

AR600 Steel Body Armor Plates 

AR600 has the highest hardness of the three options, making it lighter, thinner, and able to stop more rounds. 

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Despite their higher hardness level, AR600 plates maintain a thickness similar to the AR550 plates. However, thanks to their advanced composition, they manage to deliver superior protection without increasing weight.

While all three plate levels &#; AR500, AR550, and AR600 &#; offer protection against rifle fire, the choice between them will depend on the specific threats the wearer expects to encounter, tolerance for weight, as well as budget.  

Brinell Hardness Scale

The Brinell Hardness Scale is an empirical test that measures the hardness of materials through the scale of penetration of an indenter. This scale is essential in evaluating body armor plates, especially those like the AR500 and AR600 steel body armor plates. It quantifies the armor plate&#;s resistance to indentation from ballistics, which essentially equates to its ability to resist penetration. A higher Brinell hardness number denotes a higher level of hardness, which translates to improved resistance against impact and penetration. However, it&#;s important to remember that a plate&#;s performance against larger caliber rounds also depends on factors such as velocity, bullet design, and bullet composition.

Bullet Velocity

The velocity of a bullet plays a significant role in its ability to penetrate body armor. Several factors can impact the velocity of a bullet, such as the barrel length of the firearm used to fire the bullet, the amount and type of gunpowder in the cartridge, the bullet&#;s shape, and the environmental conditions at the time of firing, and distance.  

A bullet&#;s speed directly correlates with the amount of kinetic energy it possesses. Therefore, a bullet with a higher velocity typically has a greater chance of penetrating armor. Factors like air resistance and the angle at which the bullet strikes can also impact the bullet&#;s velocity and, therefore, its potential for penetration.

Bullet Design

The design of a bullet can also significantly impact its penetration capabilities. For instance, full metal jacket (FMJ) bullets are designed for penetration, featuring a soft lead core surrounded by a shell of harder metal, and steel penetrating tip in the case of M855. In contrast, hollow point bullets are designed to expand upon impact, creating a larger wound channel but offering less penetration. The shape of the bullet can also affect its aerodynamics and the amount of energy it can deliver to the target, influencing its ability to penetrate body armor.

Bullet Composition

Finally, the materials used to make a bullet can impact its penetration capabilities. For instance, bullets made of lead, a relatively soft metal, tend to deform upon impact and are generally less effective at penetrating armor. In contrast, bullets made of harder materials, like steel or tungsten, or those featuring a steel or tungsten core, are typically more capable of penetrating body armor. 

The Brinell Hardness Scale is a valuable tool for evaluating the hardness and penetration resistance of body armor, it&#;s essential to consider other factors, including bullet velocity, design, and composition, when assessing overall protection levels.

Is Spall & Fragmentation a Concern with Steel Body Armor Plates?

Absolutely, I&#;ll give it to you straight, uncoated steel, or only base-coated steel will frag you if you get hit. This is why Taction includes a full build-up coat on all of the steel armor we sell at no extra cost. Companies that do otherwise are part of the reason steel armor has gotten a bad rap. 

Fragmentation and spall are two separate things that happen to steel body armor when struck by a round.

Spalling refers to the flakes or fragments of the steel plate that are dislodged upon bullet impact. These fragments can then be propelled away from the plate at high speeds, posing a risk to the wearer. Fragmentation, on the other hand, refers to pieces of the bullet that break apart upon impact, which can also be sent flying at high velocities. Both these phenomena can cause injury, even if the bullet itself doesn&#;t penetrate the armor.

However, various techniques can mitigate the risks of spall and fragmentation. One of the most common is the application of a protective coating on the steel plate. This coating is designed to absorb the impact and capture any fragments or spall that may be produced, helping to prevent them from causing injury. These coatings are typically made from durable materials that can withstand the impact of a bullet and are designed to flex or give slightly upon impact to capture the fragments.

Another way to mitigate the risk of spall is to use trauma pads behind the armor plates. Trauma pads are made from non-ballistic materials and are designed to reduce blunt force trauma by absorbing and dispersing the energy from the bullet&#;s impact.

Remember, while steel body armor plates provide protection against various threats, it&#;s important to understand the risks and mitigating factors associated with their use, and buy quality plates from a reputable company that uses methods to mitigate the risks. By taking steps to minimize the potential for spall and fragmentation, you can significantly enhance your safety and that of those around you.

Steel vs Ceramic Body Armor

The choice between steel and ceramic body armor depends on a variety of factors, including the level of threat you expect to face, the weight and comfort of the armor, and the cost. Both types of armor have their advantages and disadvantages, and understanding these can help you make an informed choice.

Ballistic Protection and NIJ Ratings

In terms of NIJ ratings, steel armor is limited to level III based on the design, and cannot stop armor piercing rounds to achieve NIJ level IV. Ceramic body armor can be found in Level III and Level IV, as well as special threat plates depending on the specific armor. Steel armor, be it AR500, AR550, and AR600, will not stop armor piercing rounds, and is often vulnerable to M193, a very fast 5.56 round.

Longevity

Steel armor has a longer shelf life than ceramic armor. Steel plates can last decades if properly stored and not exposed to severe impacts or corrosive environments. Ceramic plates are quite durable, but can degrade over time, especially if dropped or subjected to harsh conditions. Generally, ceramic plates have a warranty period of 5 to 7 years.

Weight and Comfort

Level III steel body armor plates tend to be heavier than ceramic plates. This increased weight can make them less comfortable to wear for extended periods. On the other hand, ceramic plates are lighter but also thicker, making them a preferred choice for situations that require mobility and comfort over long durations. Steel armor of a higher Brinell Hardness will make for lighter weight steel plates compared to something like AR500.

Durability

Steel is incredibly durable, more so than ceramic. It is less likely to crack or break compared to ceramic. Ceramic plates can crack if dropped or hit hard, although most companies do pad the ceramic. This doesn&#;t necessarily mean they will fail when struck by a bullet, but it can decrease their effectiveness.

Thickness and Moldability

Steel plates are thinner than ceramic plates, making them a more concealable option. The thinness of steel plates makes them more comfortable to wear. A quality plate with a full built-up coat should be .60 of an inch, give or take. Most ceramic plates are about an inch in thickness, making them a bit less comfortable. 

The choice between steel and ceramic body armor depends on your specific needs and circumstances. While steel offers more durability and a longer lifespan, ceramic provides a lighter, more comfortable solution with protection against higher threat levels.

Steel/AR500/AR600 Plates FAQ 

Final Thoughts on AR500/AR600 Armor

Steel body armor, including AR500, AR550, and AR600, offers a unique blend of durability, longevity, and cost-effectiveness that sets it apart in the world of personal protection. While they might be heavier than their ceramic counterparts, their potential for multi-hit capacity and their robustness make them a favored choice for many people. However, choosing the right body armor ultimately depends on individual needs and the nature of the threats one is likely to encounter.

It&#;s important to remember that no armor is completely bulletproof. Rather, these plates are designed to reduce the lethality of incoming rounds and protect vital organs. Steel plates like AR500, AR550, and AR600 offer significant protection, but they should be used in conjunction with other safety measures, like good tactical training and situational awareness.

Overall, whether you opt for AR500, AR550, or AR600 armor, investing in protective gear is a great first step towards ensuring personal safety in high risk situations. Always assess your needs carefully, research thoroughly, and don&#;t hesitate to seek professional advice to ensure you&#;re making an informed decision.

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

The company is the world’s best ar-500 steel supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.