Interceptor Body Armor (1999-2010)
Following the introduction of the PASGT system, another type of vest, Ranger Body Armor (RBA), was developed by the Army Soldier Systems Center at Natick Labs in the 1990s to meet the unique requirements of the Army Rangers, and would go on to greatly influence future systems. First seeing initial use during the Gulf War in 1991, the RBA system was the first step towards a new generation of protective equipment. It used the same ballistic inserts as in the PASGT vest, but also had a front ceramic plate made of aluminum oxide, which protected the torso from 7.62mm rounds. A new type of ceramic hard armor, the Small Arms Protective Insert (SAPI), was made for the RBA system. These plates are made with boron carbide or silicon carbide ceramic, extremely hard and durable materials, capable of withstanding 7.62x51mm and .30-06 Springfield rounds. They are backed by a shield made of Spectra, lightweight spun strands of ultra high molecular weight polyethylene, a high-density thermoplastic, which stops projectiles.
RBA proved to be highly effective during its use by Rangers in Mogadishu, Somalia, in 1993, and significantly reduced battlefield casualties and injuries. However, because early models only had a single SAPI plate at the front, the wearer was still vulnerable to enemy fire from behind. Researchers would then issue an updated version of the vest later on. It continued to see use with US Special operations forces for a decade, as well as elements of the 1st Infantry, 1st Armored, 82nd Airborne, and 101st Airborne during the peacekeeping missions in Kosovo, Bosnia and Herzegovina, and the 173rd Airborne during Operation Northern Delay in Kurdistan during the invasion of Iraq. The Army began to more favorably view modular armor systems by the end of the 1990s, realizing the importance of protecting soldiers from small arms. Three years later, in 1996, the Army began fielding the Interim Small Arms Protective Overvest (ISAPO), which consisted of front and back ceramic plates made of boron carbide stored in carriers, and like RBA provided protection against up to 7.62mm rounds. Depending on the size of the plates, it increased the weight of the vest by 12-16 pounds, bringing the total weight to 25 pounds.
Less than 4,000 ISAPO were fielded, but the concept of modular body armor did leave an impression on Army researchers. A lighter and more accessible solution to the PASGT vest was needed, and researchers at the Defense Advanced Research Projects Agency and Natick Labs created the Interceptor Multi-Threat Body Armor system. This new vest had better protection against fragmentation and small arms rounds. Interceptor was the first true system of modular body armor fielded by the United States, and while not perfect, was still able to save lives. Development of the Interceptor Body Armor system coincided with the creation of the Modular Lightweight Load-Carrying Equipment system (MOLLE), which allowed soldiers to attach multiple pouches and accessories to a single garment. Elements of the 10th Mountain Division, 82nd Airborne, 101st Airborne, and 75th Ranger Regiment along with Marine units tested early prototypes, with feedback being overwhelmingly positive. Prior to the development of the Interceptor system, previous vests had been designed mainly to protect against only fragmentation, and not small arms fire. Due to the obvious threat posed by enemy fire, Soldiers needed a system that would be able to stop projectiles in their tracks, especially high-velocity rounds. The SAPI plates could resist 9mm parabellum handgun rounds, and with ballistic inserts added could stop 7.62mm ball ammunition. Though it weighed nearly twice as much as the PASGT vest, the Interceptor gave much better protection.
Overview
Two versions of the IBA system were produced: Gen I, in service from the early 2000s and Gen II, made specifically for the Army in the Universal Camouflage Pattern (UCP), with several improvements over the previous generation. Interceptor’s entry into service was first announced in 1998. Production of Gen I began in 1999, two years prior to the start of the Global War on Terror. The basic system consisted of a vest, yoke and collar assembly, throat protector assembly, and a groin protector. The vest, referred to in later models as the Outer Tactical Vest (OTV) had a front and back carrier for ceramic plates. The front and back carriers were made of ‘soft armor’ - spun M2 Kevlar, and without plates weighed only 7.7 pounds. Both of these parts are bullet and heat resistant, offering better protection than the PASGT vest. SAPI plates were adapted for use with the system, and were 50% lighter than RBA ones. Interceptor would first see widespread use in Operation Enduring Freedom in Afghanistan and Operation Iraqi Freedom.
Above: C-SPAN, Washington, February 2006: PEO Soldier and Army HQ Colonels demonstrate how to open and remove the front SAPI plate from the OTV.
The IBA was designed to be compatible with the MOLLE system, and rows of PALS webbing on the front and back were added to allow the attachment of MOLLE gear, altering the distribution of weight to the torso and making it more even. Prior to the development of the Interceptor system, previous vests had been designed mainly to protect against only fragmentation, and not small arms fire. Due to the obvious threat posed by enemy fire, Soldiers needed a system that would be able to stop projectiles in their tracks, especially high-velocity rounds. The SAPI plates could resist 9mm parabellum handgun rounds, and with ballistic inserts added could stop 7.62mm ball ammunition. The fit could be adjusted and re-adjusted using nylon webbing at the side to accommodate the wearer’s size. Front panels had a pocket for Enhanced Small Arms Protective Insert (ESAPI) that allowed the wearer to quickly eject the hard armor insert, and were connected to the back panel with three pieces of nylon webbing at each side and also attached to the shoulders, secured by hook and loop and snap fasteners.
A fighting load carrier (FLC) vest could be worn over the OTV, allowing for the attachment of additional pouches and gear. The back carrier’s PALS webbing made it possible to mount hydration packs, field packs and other MOLLE gear to ensure the wearer had everything it needed for missions in the field. Later OTVs had a square-shaped strip of velcro for attachment of rank insignia, and a rectangular strip for the wearer’s name. The front right panel had an ESAPI pocket that could be inserted or removed while wearing the vest. Soft and hard armor came in a total of five sizes, and was inserted into the outer shell. With SAPI plates, the vest weighed 15.7 pounds, and 24 pounds with E-SAPI. SAPI could withstand hits from rounds up to 7.62x51mm, and E-SAPI, designed to offer improved protection from other threats, could withstand hits up to .50 caliber. The yoke-and-collar assembly came with two ballistic inserts, giving additional protection to the neck and throat, and the throat protector assembly came with a single ballistic insert. The back panel had an ESAPI pocket that could be accessed while wearing the vest. A large handle was located on the back, just below the collar, which allowed a wounded soldier to be dragged to safety.
Above: A mortar crew from the 173rd Airborne, wearing the new ACU in the
digital UCP pattern along with older DCU Interceptor vests, FLCs and ACH helmets.
The groin protector assembly was attached to the inside of the front carrier with two nylon straps and fasteners, and gave protection to the pelvis and femoral arteries. Body armor became an issue in Iraq soon after the March 2003 invasion. The Army initially gave ceramic plates to front-line soldiers, but insurgents attacked US troops wearing vests, so the Department of Defense would end up procuring more than 300,000 sets of Interceptor vests and SAPI plates. The increased use of Improvised Explosive Devices (IEDs) in Iraq and Afghanistan led the Army to adopt the Deltoid and Axillary Protectors (DAPS). These began to be fielded in the mid-2000s, and were a key feature of the 2nd generation of Interceptor Body Armor. Gen II OTVs have a few differences; they were produced in the UCP camouflage pattern, have several rows of PALS webbing on the back, and were typically worn with DAPs and ESBI. The DAPS provide protection to the upper arm and shoulder areas from shrapnel and fragmentation. It consists of a deltoid protector assembly and axillary protector assembly, each with an outer shell component and ballistic insert. It was compatible with both the OTV and the IOTV, secured around the arm of the wearer with a strap. The axillary protector is worn under the OTV and is attached to the underside of the shoulder portion of and to the interior adjustment strap on the lower side. Interceptor would later be replaced by the Improved Outer Tactical Vest (IOTV) beginning in 2007.
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