Being able to move around comfortably in body armor is important for wearers to maximize their efficiency, whether in combat or other security or surveillance functions. DuPont, the originators of Kevlar, developed a new version called Kevlar EXO.

According to the company, the new aramid fiber can reduce the weight of body armor by 30 to 40%, at the same time gaining strength and flexibility and making the material more environmentally friendly.

“We created a new manufacturing process for the fiber, “ said Steven LaGanke of DuPont Life Protection, during a recent interview with Design News. According to LaGanke, DuPont has spent close to decade developing Kevlar EXO. While the material can be used in a number of applications, LaGanke said body armor was a primary application due to changing demographics of security and military personnel and the increasing amount of technology these personnel must wear in the field.

LaGanke noted, for example, that soldiers increasingly carry portable radios and tech gear in the field, adding weight and making it imperative that their body armor be made lighter to compensate for the added weight and give them the flexibility to quickly maneuver and move around.

LaGanke added, “More females are entering law enforcement,” LaGanke said. Because of their generally smaller body sizes than males, it was even important to lighten Kevlar to make the material more comfortable for them.

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Besides flexibility, Kevlar EXO is inherently flame-retardant and temperature-resistant, and melt and ignite-proof up to 500◦C, suiting it for difficult outdoor environments. The material is recyclable through DuPont’s partners.

According to LaGanke, Kevlar EXO is already being designed into body armor through DuPont’s military customers. Besides body armor, other potential applications for Kevlar EXO include mining, fiber optics, aerospace, automotive, and ropes and cables.