10 Questions You Should to Know about Uhmwpe Plastics Plates

What is UHMW-PE?

UHMW-PE stands for Ultra High Molecular Weight Polyethylene. It is the highest quality polyethylene (PE) available, engineered for tough jobs and a wide range of applications. It delivers savings in a number of difficult applications. Ultra High Molecular Weight is the secret of this polymer’s unique properties. Its high-density polyethylene resin has a molecular weight range of 3 to 6 million, compared to 300,000 to 500,000 for high molecular weight (HMW) resins. That difference is what ensures that this material is strong enough to withstand abrasion and impact better than lower level poly products. UHMW-PE’s high molecular weight means it will not melt or flow as a molten liquid. Processing methods are therefore derived from those of powder metal technology. UHMW-PE cannot be transformed and molded by conventional plastic processing techniques (injection molding, blow molding or thermoforming). Compression molding is the most common conversion process used with this resin because it produces a stronger, more consistent product.

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What is TIVAR®?

TIVAR® is the brand name (from Poly-Hi) for a special formulation of ultra high molecular weight polyethylene (UHMW-PE). UHMW-PE is a unique family of high-density polyethylene with a molecular weight 3 million or higher. UHMW-PE is a high performance polymer with a high melt viscosity that can be extruded, fabricated or compression molded.

What does TIVAR® stand for?

TIVAR® is an acronym for Tough Inert Very Abrasion Resistant.

What are the key properties of TIVAR® UHMW-PE?

TIVAR® is known for its high abrasion resistance, natural lubrication, high impact strength, chemical-, corrosion-, and moisture-resistance and acoustic impedance.

Why use TIVAR®?

Due to its abrasion-, corrosion-, chemical- and moisture-resistant properties, TIVAR® is commonly used in applications where conditions may be too harsh for other materials. It is a cost-effective high performance polymer used to produce low cost, high quality parts.

How does TIVAR® compare to other materials?

In most cases, TIVAR® will out-wear materials such as Nylon, Teflon® or Acetal. It can also outperform metals such as steel and aluminum when used in the proper applications. Material performance is of course dependent on the specific environmental conditions.

Where is UHMW used?

UHMW is a self-lubricating material which exhibits excellent wear and abrasion properties as well as adding extremely high impact strength. A few of the markets which would utilize these attributes would be snowboard bottoms, package handling, packaging, food processing and automotive.

What are the benefits of UHMW-PE?

The high molecular weight is what gives UHMW-PE a unique combination of high impact strength efficient of friction and abrasion resistance that outwears carbon steel 10 to 1 making it more suitable for applications where lower molecular weight grades fail.

Are UHMW-PE USDA and FDA approved?

Yes, UHMW-PE is both FDA and USDA approved for use in food processing and medical applications.

How do you differentiate UHMW from HDPE?

There are three tests you can perform:

1. Burn Test – light it with a match and smell the smoke. If it smells like candle wax – that indicates polyethylene. UHMW does not drip as readily as HDPE but it will drip.
2. Oven Test – place it in an aluminum dish in a 300 degree oven. Regular HDPE will slump or melt but UHMW will not change size or shape. However, it could warp or distort due to built in stresses.
3. Saw Test – When cut with a saw, regular HDPE gives sawdust or filings while UHMW gives strings or nothing.

What is the temperature range of UHMW?

UHMW-PE can operate continuously up to 180 degrees F and intermittently at 200 degrees F with custom blends available to enhance the temperature range up to 300 degrees F. UHMW-PE can perform without degradation at extremely low temperatures (-452 degrees F).

What are the heat characteristics of UHMW?

The sustained high temperature use is 180 degrees F and the intermittent use is 200 degrees F.

Does UHMW degrade at higher temperatures?

Not for short times but for longer times above 200 degrees F it loses mechanical properties, abrasion and impact.

What chemicals affect UHMW?

Water solutions are generally safe except highly oxidizing chemicals such as bleach. Hydrocarbons such as gasoline, kerosene, oil and grease cause swelling. Chlorinated solvents cause swelling. Organic alcohols, ketones and acids have little effect.

How does the environment affect UHMW?

• Wind – no effect
• Rain or sea water – no effect
• Sun without protection – depends on thickness and location. The thicker the better. In Florida, Arizona, New Mexico, and other desert areas – less than one year.

What is the flammability of UHMW?

UHMW has no UL recognition. It would be HB on UL-1 – that is slow burning (less than 3″ per minute).

How can you tell if a sample of UHMW contains regrind?

It is hard to tell – maybe some black or other colored specks might be present. The only way to determine is by a sand slurry test. After that test, it would tend to feel stiffer or harder. There may be some increase in modules. If the resin has been reprocessed many times, abrasion and impact resistance can greatly affected.

Can UHMW be used for underwater applications?.

Yes, UHMW does not absorb water and is chemically inert.

How does UHMW protect metal from wearing away?

UHMW has the highest abrasion resistance of any thermoplastic polymer. When used as a wear liner, UHMW will not cake or stick to metal. It also offers excellent noise abatement in material handling applications.

Is it necessary to grease or oil UHMW?

No, UHMW is a self-lubricating polymer and requires no additional lubrication.

Is UHMW affected by cryogenics?

Hydrogen and nitrogen don't affect it, but oxygen could.

Are there any high performance blends that can be added to UHMW-PE?

UHMW manufacturers have done extensive research on numerous additives that can enhance a property of UHMW-PE thereby providing customized products to meet customer requirements.

Is TIVAR® H.O.T weldable?

Yes

Is TIVAR® H.O.T available in other colors?

No, only pigmented white (the standard, stock color) and black FDA can be made. For black, minimum order amounts would apply. Other colors would bleed out at higher temperatures, and therefore something you would want to avoid.

What other colors of UHMW-PE are available?

While natural (milky white) and black are standard stock colors, UHMW-PE can be produced in a variety of Pantone colors.

Does TIVAR® melt or freeze?

Although TIVAR® never actually melts, it will begin to lose its excellent properties at a temperature of 180 degrees F (82 degrees C). TIVAR® will generally perform very well down to cryogenic temperatures, but like other plastics, it will expand and contract with variations in temperatures.

Is UHMW available in a conductive or anti-static form?

UHMW can be manufactured in conductive or anti-static forms making it ideal for use in electronics and semi conductor applications.

Is UHMW UV stable?

In its natural state, UHMW-PE is not UV stable, but formulations are available to provide UV stability in natural, black or any custom color.

Many people ask: can I coat UHMW on wear surfaces?

No, you can’t coat UHMW on because of two reasons: It does not melt to form a continuous surface.; It requires pressure to weld all the unmelted particles at high temperatures.

Is there an alternative to coating parts?

Yes, wear tape is a thin film of UHMW with adhesive backing than can be bonded to the surface.

In what form are UHMW-PE film and tape available?

UHMW can be made in films .003″ through .125″ thick in continuous coil from ¼” up to 24″ wide and cut to length in pieces and in stamped parts.

What kind of tolerances can you get with TIVAR®?

Tolerance levels are dependent on the manufacturing method and part design. Contact us for specific technical data.

Can UHMW be ultrasonically welded?

Yes, again the process is much like regular HDPE. Thick sections of UHMW may be more difficult than HDPE because of lower modules. If the plastic is softer, like UHMW, more attenuation of the ultrasonic energy occurs.

Can UHMW be thermal welded?

Yes, it behaves much like regular HDPE. The minimum temperature is 400 degrees F and the minimum pressure of 300 psi is highly recommended.

What percentage of parent strength of UHMW can be attained?

0.8%.

Can adhesives be used to secure UHMW liners?

Not for most applications. The reason is the large difference between the coefficient of thermal expansion of metal and UHMW puts high stresses on the bond if the bond encounters temperature extremes.

What are my installation options for UHMW?

There are two methods of adhering – the use of pressure sensitive systems (peel and stick) and allowing UHMW-PE to be bonded using epoxy systems or contact cements. A traditional metal mechanical fastening can also be used if preferred.

Can UHMW be formed into a curved liner?

Bending or folding sheet can be done efficiently above the melt point  at 300 degrees F. At that temperature, it shapes easily. However, it must be fastened in the bent or folded position until cooled.

How thick should UHMW liners be?

The minimum UHMW thickness is usually 1/4″. The liner should be thicker in impact areas and thinner in slide areas. Important notes: UHMW cannot be firmly fastened to metals because of a large difference in thermal expansion. UHMW expands five times as fast as steel and three times as fast as aluminum and about the same as wood but slightly more than concrete.

What is the best way to secure UHMW liners to metal?

Fasteners are the best way to secure UHMW to metal. The UHMW must be allowed to expand or float. Large flat head fasteners must be used. Fastener shaft holes in UHMW must be over-sized to allow for sheet expansion and contraction.

What is Polyethylene Armor? 

Polyethylene (PE) body armor plates, also known as UHMWPE ballistic plates, are lightweight yet highly durable, making them a preferred option for law enforcement, military, and security professionals.

Unlike traditional steel or ceramic armor, polyethylene ballistic plates leverage high-density polyethylene fibers that are layered and compressed to create a strong, impact-resistant structure. This advanced body armor technology provides multi-hit protection while maintaining superior mobility and comfort.

It's important not to confuse polyethylene armor plates with polyurethane materials commonly used in costumes or non-ballistic applications. Throughout this article, we’ll explore the key advantages and drawbacks of PE armor plates, how it compares to other materials, and why it's an excellent choice for modern tactical applications.

Pros of Polyethylene Body Armor

In recent years, polyethylene body armor plates have become the preferred choice for security personnel, law enforcement officers, and military professionals. The rise in popularity is due to UHMWPE armor's lightweight, high strength, and superior durability, making it a leading alternative to Kevlar® and steel body armor. Let’s break down the most important benefits.

Lightweight Yet Strong: Polyethylene plate armor is among the lightest hard armor options available. With an exceptional strength-to-weight ratio, UHMWPE armor plates reduce fatigue, allowing wearers to move freely without compromising protection. For those who need all-day wear, PE body armor significantly cuts down on strain, unlike traditional steel armor.

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Resistant to Water & Corrosion: Unlike steel body armor, which is prone to rust and corrosion over time, polyethylene armor is waterproof. This makes UHMWPE ballistic plates ideal for high-humidity environments, maritime operations, or prolonged field use without the risk of material degradation.

Cons of Polyethylene Body Armor

While UHMWPE ballistic plates offer exceptional weight savings and protection, there are a few trade-offs to consider before choosing polyethylene armor.

Heat Sensitivity & Extreme Temperatures: Polyethylene armor remains structurally sound under most conditions but can start softening at prolonged exposure above 180°F (82°C). To ensure long-term effectiveness, avoid prolonged storage in vehicles or direct heat sources above 200°F (93°C). UHMWPE’s melting point is approximately 265°F (129°C), but its ballistic integrity declines before reaching this temperature. This can be mitigated with proper plate storage.

Higher Cost Compared to Steel or Ceramic: UHMWPE body armor is more expensive than steel armor due to advanced material processing and manufacturing costs. However, its long-term durability, lightweight benefits, and lack of corrosion risk make it a worthy investment for those seeking high-performance ballistic protection.

Increased Thickness: While polyethylene plates are lighter than ceramic and steel plates, they tend to be thicker. This can impact concealability, making them less suitable for low-profile or discreet wear under clothing.

How Does Polyethylene Body Armor Compare To Other Types of Body Armor?

Choosing the right body armor plates is crucial for balancing weight, protection, and mobility. Understanding how polyethylene ballistic plates compare to steel, ceramic, Kevlar®, and soft armor helps in making an informed decision.

Below, we break down the pros and cons of polyethylene armor vs. other common body armor materials so you can setup your plate carrier with plates that work for you.

Polyethylene Body Armor vs Steel Body Armor

• Steel armor offers edge-to-edge protection, meaning every inch of the plate stops bullets.
• However, steel plates create dangerous spalling (bullet fragmentation that can injure the wearer) unless coated with anti-spall layers or covered with a spall liner.
• UHMWPE ballistic plates are 50-60% lighter than steel, reducing fatigue.
• Polyethylene armor absorbs impact rather than deflecting it, preventing secondary injuries.

Polyethylene Body Armor vs Ceramic Ballistic plates

• Ceramic body armor is cheaper but are brittle and prone to cracking after impact.
• UHMWPE plates can withstand multiple hits, whereas ceramic armor degrades with each bullet impact.
• PE plates are more durable, making them a better investment for long-term use.

Polyethylene Body Armor vs Kevlar Body Armor

Polyethylene body armor and Kevlar body armor are both highly effective and durable materials. Kevlar® contains synthetic fibers that feel more more like thick clothing.

• Kevlar® soft armor is effective against handguns, while polyethylene rifle plates stop rifle rounds.
• Kevlar® is thinner and more concealable, but UHMWPE plates provide superior rifle protection.

Polyethylene Body Armor vs Soft Body Armor

• Soft armor, like Kevlar®, is lightweight and flexible, but does not protect against rifle threats.
• Polyethylene body armor is designed for high-threat environments requiring rifle-rated protection.

Despite its impressively low weight, polyethylene armor isn’t as discreet as most soft body armor due to its increased thickness.

Polyethylene Body Armor vs Hard Body Armor

• Hard armor includes steel, ceramic, and polyethylene plates.
• UHMWPE ballistic plates are the lightest hard armor option, combining high-level protection with comfort.

Feature Polyethylene Steel Ceramic Soft Armor (Kevlar®) Weight Lightest hard armor option Heaviest Moderate Lightest overall Protection Level Rifle-rated (Level III & IV) Rifle-rated (Level III+) Rifle-rated (Level III & IV) Handgun-rated (Level II & IIIA) Durability Long-lasting, resistant to moisture Most durable, but can rust Brittle, cracks easily Flexible but can degrade over time if worn frequently Heat Resistance Sensitive to extreme heat Excellent Good Good Cost Moderate to High Budget-friendly Moderate Varies (Low-Moderate) Spalling Risk None High (requires anti-spall coating) None None

Choosing the right body armor depends on your specific needs:

• Polyethylene plates offer the best combination of weight, protection, and durability, making them ideal for law enforcement, security professionals, and anyone seeking rifle-rated protection without excessive weight.
• Steel armor is the most budget-friendly, but its heavy weight and risk of spalling make it less ideal for prolonged wear.
• Ceramic plates offer solid protection but can crack after impact, making them less durable for multiple threats.
• Soft body armor (Kevlar®) is the best option for day-to-day wear and concealability, but it is not rifle-rated.

For those prioritizing lightweight protection with high ballistic resistance, polyethylene body armor is the clear winner. If you're on a budget and need rifle-rated armor, steel may be a reasonable alternative—but keep in mind its weight and spalling risks. If discreet protection against handguns is the priority, soft armor is an excellent choice.

Why You Should Consider Lightweight Polyethylene Armor

When choosing body armor, striking the right balance between weight, protection, and comfort is crucial. Polyethylene armor stands out as the best lightweight option for those seeking rifle-rated defense without the burden of heavier materials like steel or ceramic. Here’s why:

Ultra-Lightweight Construction: Polyethylene plates are up to 60% lighter than steel or ceramic plates, significantly reducing fatigue for law enforcement, security professionals, and military personnel who wear armor for extended periods. Our Stratis Level III+ Multi-Curve plate is the lightest option at just 3lbs.

High Protection Levels: Despite their lightweight build, UHMWPE plates meet NIJ Level III and IV standards, stopping powerful rifle rounds without excessive bulk. They also feature multi-hit capability, ensuring continued protection even after multiple impacts.

Unmatched Comfort & Mobility: The reduced weight and shock-absorbing structure of polyethylene plates allow for quicker movement and easier maneuverability—a critical factor in high-stress tactical situations.

Durability & Environmental Resistance: Unlike steel, polyethylene armor won't rust or corrode, and it is highly resistant to moisture, making it perfect for humid, maritime, or wet environments. Unlike ceramic, polyethylene plates won’t shatter upon impact, ensuring consistent protection.

Bottom Line: If you want the most comfortable, durable, and lightweight rifle-rated protection, polyethylene armor is the best choice.

We offer poly plates level 3 as well as our level 4 polyethylene body armor. Different situations require different levels of protection. Learn more about body armor ratings to find out which treat level of protection is best for you.

How is Polyethylene Body Armor Made?

The process of creating polyethylene body armor is highly specialized, combining advanced engineering, heat compression, and ballistic science to produce lightweight yet incredibly strong protective plates. Here’s how it's done:

1. Producing UHMWPE Fibers:

• Ultra-High Molecular Weight Polyethylene (UHMWPE) starts as ethylene molecules, which undergo gel-spinning, creating long, high-strength fibers.
• These fibers are stretched and aligned, increasing their tensile strength to make them bullet-resistant.

2. Weaving & Layering the Fabric:

• The fibers are woven into multiple layers, forming a fabric capable of dispersing impact energy across a broad surface.

3. Heat & Pressure Lamination:

• Under intense heat and compression, the woven UHMWPE sheets are bonded into solid armor plates.
• This fusion process enhances ballistic resistance and prevents fragmentation upon impact.

4. Precision Cutting & Shaping:

• The hardened polyethylene panels are cut into specific armor shapes (SAPI, Shooter’s Cut, Swimmer’s Cut, etc.).
• The plates are contoured to fit comfortably against the body without restricting movement.

5. Final Assembly & Protective Coating:

• Polyurea coating is applied to increase durability, resist moisture, and reduce backface deformation. You may also see plates wrapped in Cordura for durability.
• The result? Lightweight, rifle-rated armor that outperforms traditional materials in weight and resilience.

Why Does This Matter? Unlike steel or ceramic plates, polyethylene absorbs and distributes impact energy instead of breaking or ricocheting rounds. This process makes it one of the most effective, long-lasting, and advanced armor materials available today.

What You Need to Know About Ultra-High Molecular Weight Polyethylene Armor

When selecting UHMWPE (Ultra-High Molecular Weight Polyethylene) body armor, it’s crucial to evaluate factors beyond protection levels. Polyethylene plates stand out for their durability, multi-hit capability, and lightweight construction, but understanding their limitations and advantages will help you make an informed decision.

This section explores key considerations such as edge-to-edge protection, lifespan, impact resistance, and specialized use cases to ensure you select the best polyethylene armor for your needs.

What About Edge-to-Edge Protection Of Polyethylene Plates?

When shopping for plates, be sure to ask about edge-to-edge protection. You'll find some plates, like our Fortis Level IV plate, has a strike face minimally inset 0.5" to protect against drops, where other plates may have larger insets. You want as close to edge-to-edge protection as possible for the greatest area of coverage.

Regardless of your setup, always ensure your cardiac box (heart and major organs) is fully covered, as this is the most vulnerable and critical area.

What is the Shelf Life of Polyethylene Armor?

How long does polyethylene body armor last? Polyethylene armor typically has a 5-10 year lifespan, depending on manufacturer and storage conditions. Unlike ceramic, which can degrade from impact, polyethylene armor remains effective unless exposed to extreme heat or mechanical damage.

To maximize your armor’s lifespan:

• Store in a cool, dry location away from direct sunlight and extreme heat.
• Avoid moisture buildup to prevent material degradation.
• Check manufacturer guidelines for routine maintenance and testing.

At Premier Body Armor, our polyethylene plates undergo rigorous testing to ensure they meet NIJ standards for long-term durability. Each plate comes not only with a competitive warranty guaranteeing reliable ballistic protection throughout its lifespan, but also with an incident replacement guarantee.

What about PE Plate Backface Deformation?

Backface deformation (BFD) occurs when the force of a bullet impact causes the rear surface of an armor plate to bulge into your body. While some deformation is normal, excessive BFD (over 44mm) can result in serious blunt force injuries.

How do polyethylene plates minimize BFD?

• UHMWPE plates are designed to absorb and disperse impact energy, reducing the severity of backface deformation.
• Thicker polyethylene plates provide superior BFD resistance compared to steel or ceramic plates.

Choosing a thicker polyethylene plate with multi-layered construction can significantly reduce blunt force trauma while still keeping your armor lightweight and comfortable.

Are Polyethylene Rifle Plates Multi-Hit Capable?

Are polyethylene plates multi-hit capable? Some polyethylene plates, like our Fortis Level IV Plate, are engineered for multi-hit protection with a tiled composite strike face that prevents damage from spreading and cracking across the plate. However, not all UHMWPE plates are multi-hit rated—always check testing documents and NIJ certifications for confirmation.

Key Multi-Hit Benefits:

• Tiled Composite Construction: Absorbs and contains damage within localized sections.
• Lightweight Design: Offers high-level protection without excessive bulk.
• Superior Durability: Maintains ballistic integrity even after multiple hits.

While our multi-hit polyethylene plates provide exceptional protection, any armor plate that sustains direct impact should be replaced as soon as possible to ensure continued safety.

Does Polyethylene Body Armor Float in Water?

One of the unique benefits of UHMWPE body armor is its buoyancy—unlike steel or ceramic plates, polyethylene armor plates float in water. This makes them an excellent choice for maritime security personnel, military divers, and rescue operations, where being weighed down by heavy armor could be dangerous.

Key Benefits of Buoyant Polyethylene Armor:

• Does not sink like steel or ceramic armor.
• Ideal for maritime operations or humid environments.
• Maintains ballistic integrity even when wet.

However, while UHMWPE plates are water-resistant and lightweight, they should never be relied upon as a flotation device or life-saving equipment. They are designed for ballistic protection, not water survival.

Is Polyethylene Body Armor Knife Safe / Knife Resistant?

Can polyethylene body armor stop a knife? While UHMWPE armor plates are highly resistant to ballistic threats, they are not rated as fully stab-proof. The woven fibers of polyethylene plates provide some resistance to slashing, but they are not NIJ-rated for stab resistance.

Unlike dedicated stab-proof vests, polyethylene armor does not prevent piercing attacks from knives or other edged weapons.

Key Facts About Knife Resistance & UHMWPE Armor:

• Polyethylene plates may resist slashing attacks but are not tested for direct stab protection.
• "Stab vests" exist, but they are separate from ballistic-rated polyethylene armor.

For dedicated stab-resistant armor, check for NIJ-certified stab-resistant vests specifically designed for bladed threats.

Final Thoughts

The best polyethylene body armor stands out as the lightest rifle-rated protection available today, combining durability, comfort, and mobility without sacrificing ballistic performance. Whether you're in law enforcement, military, or a civilian prioritizing safety, UHMWPE plates offer a practical alternative to heavier steel or ceramic options.

At Premier Body Armor, we offer Level III and Level IV polyethylene body armor engineered for maximum protection and comfort. For those desiring a more covert solution, our polyethylene body armor backpack insert provides rifle-rated protection for most standard sized backpacks.

Contact us to discuss your requirements of 8 Inch HDPE Pipe. Our experienced sales team can help you identify the options that best suit your needs.