Draft 

NIJ Standard 0115.01

Stab Resistance of Body Armor

National Institute of Justice

March 2020
DRAFT FOR PUBLIC COMMENT

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Introduction

This draft document specifies minimum performance requirements and test methods for the 

stab resistance of body armor used by U.S. criminal justice personnel that is intended to 

protect against knife and spike stab threats. It is a proposed revision of NIJ Standard 0115.00, 

Stab Resistance of Personal Body Armor, published in 2000.1

 The final version of this draft 

document is anticipated to be published in 2021 as NIJ Standard 0115.01, Stab Resistance of 

Body Armor. Its primary purpose will be for use by the NIJ Compliance Testing Program 

(CTP) for testing and evaluation of stab-resistant body armor for certification by NIJ. It will 

be used by both laboratories that test body armor and body armor manufacturers participating 

in the NIJ CTP. This standard will be included in the Personal Body Armor scope of 

accreditation used by the National Voluntary Laboratory Accreditation Program (NVLAP) to 

accredit laboratories that test body armor.

This document uses the following in accordance with international standards: 

— “shall” indicates a requirement;

— “should” indicates a recommendation;

— “may” indicates a permission;

— “can” indicates a possibility or a capability.

Please send all written comments on this draft document to Mark Greene; Technology and 

Standards Division Director; Office of Research, Evaluation, and Technology; National 

Institute of Justice in electronic format by email at mark.greene2@usdoj.gov. 

Please send all other written comments and suggestions to the Director, National Institute of 

Justice, Office of Justice Programs, U.S. Department of Justice, 810 7th Street NW, 

Washington, DC 20531. 

Nothing in this document is intended to create any legal or procedural rights enforceable 

against the United States. Moreover, nothing in this document creates any obligation for any 

individual or organization to follow or adopt this voluntary standard nor does it create any 

obligation for suppliers, law enforcement agencies, or others to follow or adopt voluntary NIJ 

equipment standards. 

 

1 NIJ Standard 0115.00, Stab Resistance of Personal Body Armor, National Institute of Justice, U.S. Department 

of Justice, Washington, DC, September 2000, https://www.ncjrs.gov/pdffiles1/nij/183652.pdf. 
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Table of Contents 

1. Scope................................................................................................................................................ 4

2. References........................................................................................................................................ 4

3. Terms and Definitions ..................................................................................................................... 5

4. Test Threats, Equipment, and Materials .......................................................................................... 7

5. Armor Protection Levels .................................................................................................................. 9

6. Armor Performance Requirements.................................................................................................. 9

7. Armor Test Items: Requirements and Utilization.......................................................................... 10

8. Procedure for Visual Examination of Test Items........................................................................... 11

9. Stab Test Requirements and Pre-test Procedures........................................................................... 15

10. Stab Test Procedure ....................................................................................................................... 21

11. Test Report..................................................................................................................................... 21

Annex A (Mandatory): Test Threat Drawings and Requirements......................................................... 22

Annex B (Mandatory): Stab Test Apparatus, Requirements, and Setup ................................................ 30

Annex C (Mandatory): Equipment and Procedure for Conditioning Soft Armor by Submersion ......... 37

Annex D (Mandatory): Template for Test Item Size ............................................................................. 38

Annex F (Mandatory): Diagrams showing impact locations for planar test items ................................ 44

Annex G (Mandatory): Soft Armor Designed for Female Wearers....................................................... 45

Annex H (Mandatory): Conversion Tables for Penetration Depth ........................................................ 49
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1. Scope

1.1. This standard specifies minimum performance requirements and test methods for stabresistant body armor intended to protect against stab (i.e., edged blade and spike) 

threats for U.S. criminal justice personnel. 

1.1.1. The test methods within this standard were developed and validated for broadly 

available armor designs. Some armor designs may require additional or modified

testing than that specified in this standard. 

1.2. This standard addresses only stab-resistant panels intended to protect the torso and 

does not address extremity protection.

1.3. Body armor covered by this standard is classified into two protection levels based on 

mission requirements and threats anticipated to be encountered within the distinct 

operational environments:

1.3.1. Commercial threat protection: Commercially made knives and spikes, typically 

encountered outside of controlled access facilities or within the jail in-take area.

1.3.2. Improvised threat protection: Improvised or inmate-made weapons, typically 

encountered inside controlled access facilities, such as jails, detention centers and 

prisons.

1.4. This standard does not address ballistic-resistant body armor.

1.5. This standard is applicable for certification testing or research and development 

testing.

1.6. This standard incorporates other standards from ASTM International and ISO/IEC.

1.7. The values stated in SI units are to be regarded as standard. The values given in 

parentheses are mathematical conversions to inch-pound units that are provided for 

information only and are not considered standard.

1.8. The tests required by this standard have inherent hazards. It is the responsibility of the 

user of this standard to establish appropriate safety and health practices and to comply 

with regulatory requirements.

2. References

The following references form a basis and provide support for the requirements and 

procedures described in this standard. For dated references, only the edition cited applies. For 

undated references, the latest edition of the referenced document applies, including any 

amendments.

2.1. An Assessment of Human Performance in Stabbing 1999. Shrivieham, UK: Royal 

Military College of Science. https://dspace.lib.cranfield.ac.uk/handle/1826/4930

2.2. ASTM D1056-14 Standard Specification for Flexible Cellular Materials-Sponge or 

Expanded Rubbers. West Conshohocken: PA: ASTM International.

2.3. ASTM D2240-14 Standard Test Method for Rubber Property—Durometer Hardness. 

West Conshohocken: PA: ASTM International.
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2.4. ASTM E3005-18. Standard Terminology for Body Armor and Related Items. West 

Conshohocken: PA: ASTM International. 

2.5. ASTM E3086-17. Standard Practice for Creating Appliques for Use in Testing of 

Nonplanar Soft Body Armor Designed for Females. West Conshohocken: PA: ASTM 

International. 

2.6. ASTM D3575-14 Standard Test Methods for Flexible Cellular Materials Made From 

Olefin Polymers. West Conshohocken: PA: ASTM International. 

2.7. ASTM D4819-13 Standard Specification for Flexible Cellular Materials Made From 

Polyolefin Plastics. West Conshohocken: PA: ASTM International. 

2.8. ASTM D5264-98 (2011) Standard Practice for Abrasion Resistance of Printed 

Materials by the Sutherland Rub Tester. West Conshohocken: PA: ASTM 

International. 

2.9. Croft, J. and D. Longhurst 2007. HOSDB Body Armour Standards for UK Police. Part 

3: Knife and Spike Resistance.., St. Albans, UK: Home Office Scientific Development 

Branch. 

2.10. ISO/IEC 17025. General requirements for the competence of testing and calibration 

laboratories. Geneva, Switzerland: ISO/IEC.

2.11. Law Enforcement Officers Killed and Assaulted, 2009. Washington, DC: U.S. 

Department of Justice, Federal Bureau of Investigation. 

2.12. NIJ Standard-0115.00, Stab Resistance of Personal Body Armor. Washington, DC: 

U.S. Department of Justice, National Institute of Justice. 

3. Terms and Definitions

3.1. The following terms from ASTM E3005, ASTM E3078 and ASTM E3086 are 

applicable2

: 

3.1.1. angle of incidence, n - the angle between the test threat line of aim and the line 

normal to a reference plane based on the front surface of the backing assembly or 

witness panel. (Terminology E3005). 

3.1.2. applique, n. - a three-dimensional item molded from backing material that is 

shaped and sized for testing or conditioning a nonplanar test item. (Terminology 

E3005). 

Discussion - Some appliques are designed for the purpose of filling the entire 

space behind a nonplanar test item; other appliques are designed to assess features 

of a nonplanar test item.

3.1.3. armor carrier, n - See carrier.

 

2 Reprinted, with permission, from E3005-15 Standard Terminology for Body Armor, copyright ASTM 

International, 100 Barr Harbor Dr., West Conshohocken, PA 19428. A copy of the complete standard may be 

obtained from ASTM, www.astm.org."
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3.1.4. armor panel, n - a component of soft body armor consisting of protective 

materials, typically enclosed in a panel cover. See ballistic panel, blunt impact 

panel, stab panel. See also panel cover.

3.1.5. backing material, n - the substance placed behind the test item during testing.

Discussion - The backing material typically provides support for the test item, and 

it may act as a witness material and may provide a measurable indication of the 

test item performance.

3.1.6. body armor, n - an item of personal protective equipment intended to protect the 

wearer from threats that may include ballistic threats, stabbing, fragmentation or 

blunt impact.

Discussion - Law enforcement and corrections officers typically refer to body 

armor as a vest. See vest.

3.1.7. carrier, n - a garment whose primary purpose is to retain the armor panel(s) or 

plate(s) and provide a means of supporting and securing the armor panel(s) or 

plate(s) to the wearer.

3.1.8. conditioning, n - a process that exposes an item, prior to testing, to a specified 

controlled environment or physical stresses, or both.

3.1.9. controlled ambient, n - conditions with temperature of 20 °C ± 5.5 °C (68 °F ± 10 

°F) and 50% ± 20% relative humidity (RH). Within this standard, this definition 

applies to any direct or indirect reference to controlled ambient. (ASTM Practice 

E3078).

3.1.10. fair hit, n - a test threat impact (on a test item) that meets all specified requirements 

in a particular test method.

3.1.11. insert, n - a removable unit of protective material (soft armor or hard armor) 

intended to be placed into a special pocket on a carrier to enhance protection in a 

localized area.

3.1.12. nonplanar, adj - having features that would prevent the test item from making full 

contact with a flat surface; typically used to describe curved plates and armor 

designed for female wearers.

3.1.13. panel cover, n - a covering, typically nonremovable, that encloses the protective 

materials and protects them from environmental factors, such as moisture, 

ultraviolet light, debris and dust.

3.1.14. soft armor, n - an item of personal protective equipment constructed of 

pliable/flexible materials intended to protect the wearer from threats that may 

include ballistic threats, stabbing, fragmentation or blunt impact.

3.1.15. stop, n - See partial penetration.

3.1.16. strike face, n - the surface of an armor panel or plate intended to face the incoming 

threat.

3.1.17. test item, n - a single article intended for testing.
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Discussion - Examples may include one panel, one plate or one shoot pack. 

3.1.18. test series, n – the set of all impacts necessary to obtain the required number of fair 

hits on a single test item or the set of all impacts necessary over multiple test items 

to generate the required data. (Adapted from ASTM Terminology E3005).

3.1.19. test threat, n - the projectile, edged blade, spike or other object that is used in 

laboratory testing to impact the test item at a specific velocity or energy to assess 

performance of body armor.

3.1.20. unfair hit, n - a test threat impact that does not meet the specified requirements in a 

particular test method for impact location and spacing, velocity, angle of 

incidence, energy or other. (Adapted from ASTM E3005). 

3.1.21. witness panel, n - a sheet of material placed in a specific location and orientation to 

determine complete or partial penetration of the test item or to determine other 

performance characteristics of the test item or projectile.

3.2. The following terms are specific to this standard:

3.2.1. commercial threat, n - a commercially manufactured knife or spike. 

3.2.2. impact-to-edge distance, n - the distance from the center of the test threat impact to 

the nearest test item edge.

3.2.3. impact-to-impact distance, n - the distance from the center of the test threat impact 

to the center of any other test threat impact on the test item.

3.2.4. improvised threat, n - an inmate-manufactured knife or spike. 

Discussion - Improvised threats can be referred to as shanks or shivs. 

3.2.5. model, n - the manufacturer’s design, with unique specifications and 

characteristics, of a particular item. 

3.2.6. overtest energy level (E2), n - the energy level specified in this standard that 

corresponds to 1.5 times the primary energy value and is intended to ensure that 

the armor material performs in a linear fashion and does not suffer catastrophic 

failure at, or near, the primary energy level.

3.2.7. primary energy level (E1), n - the energy level specified in this standard at which

the armor is intended to afford protection against the applicable test threat. 

3.2.8. supplier, n - the party that is responsible for ensuring that products meet and, if 

applicable, continue to meet, the requirements on which the certification is based. 

4. Test Threats, Equipment and Materials

4.1. Test Threats

4.1.1. This standard requires two types of test threats as described below: 

4.1.1.1. Commercial Test Threats 
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4.1.1.1.1. Three commercial test threats representing kitchen knives, pocket knives, ice 

picks, awls and other similar items are required: 

• P1: Single-edged blade

• S1: Double-edged blade

• SP1: Spike

4.1.1.1.2. Testing with commercial test threats shall be done at the following energies3

: 

• Primary energy (E1): 24 ± 0.50 J (17.7 ± 0.36 ft-lbf)

• Overtest energy (E2): 36 ± 0.60 J (26.6 ± 0.44 ft-lbf)

4.1.1.2. Improvised Test Threat

4.1.1.2.1. Three improvised test threats representing edged blades and spikes made by 

inmates from materials found inside correctional facilities are required: 

• T1: Improvised single-edged blade

• T2: Improvised double-edged blade 

• T3: Improvised spike 

4.1.1.2.2. Testing with improvised test threats shall be done at the following energies4

: 

• Primary energy (E1): 43 ± 0.60 J (31.7 ± 0.44 ft-lbf) 

• Overtest energy (E2): 65 ± 0.80 J (47.9 ± 0.59 ft-lbf)

4.1.2. Detailed drawings and specifications for the test threats are provided in Annex A, 

Test Threat Drawings and Requirements.

4.2. Test Facility

The environmental conditions of the test facility shall be controlled ambient during 

testing. 

4.3. Stab Test Apparatus

4.3.1. Testing shall be performed using a stab test apparatus that meets the requirements 

below and those of Annex B, Stab Test Apparatus, Requirements, and Setup. 

 

3 The impact energy level for the commercial test threat was derived from An Assessment of Human Performance 

in Stabbing 1999. Royal Military College of Science. 24 J corresponds to the 85th percentile of the population 

that was studied. The 36 J overtest energy corresponds to 1.5 times this value and is intended to ensure that the 

armor material performs in a linear fashion and does not suffer catastrophic failure at, or near, the primary energy

level.

4 The impact energy level for the improvised test threat was derived from An Assessment of Human Performance 

in Stabbing 1999. Royal Military College of Science. 43 J corresponds to the 96th percentile of the population 

that was studied. The 65 J overtest corresponds to 1.5 times this value.
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4.4. Conditioning Equipment 

4.4.1. Equipment for soft armor test item conditioning by submersion shall meet the 

requirements described in Annex C, Equipment and Procedure for Conditioning 

Soft Armor by Submersion. 

5. Armor Protection Levels

5.1. The supplier shall declare the intended protection level for an armor model being 

submitted for testing to this standard.

5.2. Protection Level: Commercial Threat Protection

5.2.1. Armor intended to meet the commercial threat protection level shall be tested as 

specified in this standard using all of the following: 

• P1 single-edged blade test threat

• S1 double-edged blade test threat

• SP1 spike test threat

5.3. Protection Level: Improvised Threat Protection

5.3.1. Armor intended to meet the improvised threat protection level shall be tested as 

specified in this standard using all of the following: 

• T1 improvised single-edged blade test threat

• T2 improvised double-edged blade test threat

• T3 improvised spike test item

6. Armor Performance Requirements

6.1. Armor Resistance to Penetration by Commercial Threats

6.1.1. Each test item shall be tested as specified in the appropriate section of this standard 

and shall withstand the required number of fair hits and shall experience no 

penetration greater than the following: 

• 7 mm (0.27 in) at E1, for fair hits at angles of incidence of 0° and 45° 

• 20 mm (0.79 in) at E2, for fair hits at angles of incidence of 0°

6.2. Armor Resistance to Penetration by Improvised Threats

6.2.1. Each test item shall be tested as specified in the appropriate section of this standard 

and shall withstand the required number of fair hits and shall experience no 

penetration greater than the following: 
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• 0 mm (0 in) at E1, for fair hits at angles of incidence of 0° and 45° 

• 20 mm (0.79 in) at E2, for fair hits at angles of incidence of 0°

7. Armor Test Items: Requirements and Utilization

7.1. Test Item Size Requirements

7.1.1. The test items shall be provided by the supplier in size NIJ-C-4, using the size 

template provided in Annex D, Template for Test Item Size.

7.2. Soft Armor Test Item Workmanship and Construction Requirements

7.2.1. Each test item shall be free from evidence of inferior workmanship, such as 

wrinkles, blisters, cracks or fabric tears, fraying, crazing, or chipped or sharp 

corners and edges. 

7.2.2. The stitching for each test item shall be straight and secure. 

7.2.3. There shall be no variations in construction details between individual test items or 

between any test item and the supplier’s documentation for a given model. 

7.2.4. All test items shall be identical in appearance, materials and manner of 

construction, including stitch size and location. 

7.3. Soft Armor Test Item Label Requirements 

7.3.1. The label shall be permanently attached to the panel cover of the test item. 

7.3.2. The label text shall be in a readable typeface and font size, and the content shall be 

as specified in Annex E. 

7.3.3. A label affixed to one spare test item panel cover shall be tested. It shall remain 

legible and adhered to the test item following completion of the label durability 

test specified in Annex E. 

7.3.3.1. The label durability test shall not be performed on a test item that will 

subsequently undergo stab testing, unless such testing is approved by the supplier. 

7.3.4. Failure of a label to meet the above requirements is not considered a failure of the 

armor model. In the event of a label failing to meet these requirements, a case-bycase evaluation will be made by the NIJ CTP.

7.4. Soft Armor Test Item Utilization 

7.4.1. Number of required test items 

7.4.2. The number of test items required to complete a test series is dependent on 

whether the armor is to be tested in a gender-specific configuration. Tables 1, 2 

and 3 provide specify the required number of test items and how they are to be 

used. 
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7.5. Soft armor test item carrier requirements

7.5.1. Test items shall be removed from carriers prior to stab testing. 

8. Procedure for Visual Examination of Test Items

8.1. Verify the group of test items for correct quantity and size.

8.2. Examine the group of test items for variations in appearance, materials and manner of 

construction.

8.3. Examine each test item exterior to determine whether workmanship requirements are 

met.

8.4. Examine the label of a single spare test item to determine whether requirements are 

met.

8.5. Prior to conditioning by submersion, photograph at least one test item. For the 

photograph, the test item shall be lying on a flat surface and shall have a scale visible.

8.6. Following stab testing, examine the workmanship of each test item as described below 

to determine whether the requirements are met:

8.6.1. Horizontally slit only the test item panel cover with a razor blade near 

the bottom of the test item and remove the stab panel from its cover. 

Document the construction of the stab panel (e.g., layer count, material 

description, stitching). 

8.7. Document the relevant details for each test item.
Table 1. Planar Test Items: Summary of Test Item Sizes, Quantity, Conditioning and Testing 

Size and # of Test items Conditioning of Test Items Number of Test Items for Each Test

With neck scoop 1 P1 Test

Without neck scoop 1 

With neck scoop 1 

Tested at controlled S1 Test

7 Without neck scoop 1 ambient

With neck scoop 1 SP Test

Sized per NIJ-C-4 template Without neck scoop 1 

Spares Without neck scoop 1 14 test items:

6 test items with neck scoop With neck scoop 1 P1 Test 8 test items without neck scoop Without neck scoop 1 

With neck scoop 1 

Submersion per Annex S1 Test

7 Without neck scoop 1 C 

With neck scoop 1 SP Test

Without neck scoop 1 

Spares Without neck scoop 1 
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Table 2. Nonplanar Female Test Items: Summary of Test Item Sizes, Quantity, Conditioning and Testing, if the construction 

of the planar panel has not previously passed all testing requirements

Size and # of Test items Conditioning of Test Items Number of Test Items for Each Test

B-cup, with neck scoop 1 

P1 Test E-cup, with neck scoop 1 

Without neck scoop 2 

B-cup, with neck scoop 1 

S1 Test E-cup, with neck scoop 1 

Tested at controlled Without neck scoop 2 15 ambient B-cup, with neck scoop 1 

SP Test E-cup, with neck scoop 1 

Without neck scoop 2 

Sized per NIJ-C-4 template B-cup, with neck scoop 1 

Spares E-cup, with neck scoop 1 30 test items: Without neck scoop 2 8 test items are B-cup with neck B-cup, with neck scoop 1 scoop 

8 test items are E-cup with neck P1 Test E-cup, with neck scoop 1 

scoop Without neck scoop 2 

14 test items without neck scoop B-cup, with neck scoop 1 

S1 Test E-cup, with neck scoop 1 

Submersion per Annex Without neck scoop 2 15 C B-cup, with neck scoop 1 

SP Test E-cup, with neck scoop 1 

Without neck scoop 2 

B-cup, with neck scoop 1 

Spares E-cup, with neck scoop 1 

Without neck scoop 2 
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Table 3. Nonplanar Female Test Items: Summary of Test Item Sizes, Quantity, Conditioning and Testing, if the construction 

of the planar panel has previously passed all testing requirements 

Size and # of Test items Conditioning of Test Items Number of Test Items for Each Test

B-cup, with neck scoop 1 

P1 Test E-cup, with neck scoop 1 

B-cup, with neck scoop 1 

S1 Test E-cup, with neck scoop Tested at controlled 1 

8 ambient B-cup, with neck scoop 1 

SP Test E-cup, with neck scoop 1 

Sized per NIJ-C-4 template B-cup, with neck scoop 1 

Spares 16 test items: E-cup, with neck scoop 1 

8 test items are B-cup with neck B-cup, with neck scoop scoop 1 

P1 Test 8 test items are E-cup with neck E-cup, with neck scoop 1 

scoop B-cup, with neck scoop 1 

S1 Test E-cup, with neck scoop Submersion per Annex 1 

8 C B-cup, with neck scoop 1 

SP Test E-cup, with neck scoop 1 

B-cup, with neck scoop 1 

Spares E-cup, with neck scoop 1 
9. Stab Test Requirements and Pre-test Procedures

9.1. General Test Requirements

9.1.1. Any individual test item result not meeting the performance requirements shall 

constitute a failure. This applies to all test protocols unless the performance 

requirement specifically states an average result is derived for the pass/fail criteria.

9.2. Determination of Fair Hit

9.2.1. A fair hit meets all of the following conditions:

a) Has a strike energy that is within the specifications given in table 4 for the 

intended level of protection. 

b) Strikes no closer than 51 mm (2.0 in) to the edge of the armor. 

c) Strikes no closer than 51 mm (2.0 in) to the edge of the backing material. 

d) Strikes no closer than 51 mm (2.0 in) to any prior strike. 

e) Strikes the test item within ± 5° from the intended angle of incidence. 

If a penetration of greater than 7 mm (0.28 in) occurs from a strike with energy less 

than E1, but the strike would otherwise be considered a fair hit, then the strike shall be 

considered fair. 

If a penetration of greater than 20 mm (0.79 in) occurs from a strike with energy less 

than E2, but the strike would otherwise be considered a fair hit, then the strike shall be 

considered fair.

9.2.2. A strike that is delivered under more stringent conditions that results in an 

acceptable (i.e., passing) penetration shall be considered fair. The more stringent 

conditions are specifically limited to:

a) Strikes that are too close to the edge of the test item. 

b) Strikes that are too close to a prior strike. 

c) Strikes in which the strike energy is greater than the tolerances specified for the 

chosen performance level.

d) Any combination of a, b and c above. 

9.3. The kinetic energy (KE) at impact shall be calculated from:

KE = 1⁄2mv2

 Equation1 

Where: KE is kinetic energy, m is the mass of the drop mass and v is the velocity 

at approximately 6.4 mm (0.25 in) above the target surface. 

9.3.1. The result shall be documented in the test report. A determination of fair hit shall 

be made based on the strike location and impact kinetic energy. 
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9.4. If the strike is determined to be an unfair hit, then subsequent attempts shall be made 

until a fair hit is achieved.

9.5. Measurement of Penetration

9.5.1. If the strike meets the criteria for a fair hit, or if a passing penetration result (i.e., 

meeting relevant requirements of Section 6) was obtained for a more stringent hit, 

the penetration depth shall be measured and recorded on the test report.

9.5.2. Carefully separate the test item from the backing material and examine it, the 

witness paper and the backing material to determine if the test threat has penetrated 

the rear face of the test item. If any penetration has occurred, the depth shall be 

measured using the appropriate method described below.

9.5.2.1. When the rear face of the test item is not compressible, the penetration depth may 

be measured directly by placing a suitable measuring device alongside the 

protruding portion of the test threat. The length of the test threat protruding from 

the rear of the test item shall be measured and recorded. 

9.5.2.2. When the rear face of the test item is compressible, one of the two procedures

below shall be taken to determine the penetration depth:

9.5.2.2.1. For blade test threats, carefully measure the length of the cut in the test item panel 

cover or the witness panel if one was used. The tables in Annex H shall then be 

used to determine the depth of penetration.

9.5.2.2.2. For spike test threats, compress any lofted or foam materials on the rear face of the 

test item. Then, the penetration depth may be measured directly by placing a 

suitable measuring device alongside the protruding portion of the test threat. 

Note: This method applies when the rear face of the test item is compressible

because the compressible material collapses on impact and then returns to its 

original thickness. This can lead to inaccuracies when measuring the penetration 

depth.

9.5.2.3. If the drop mass bounces on impact causing the test threat to impact multiple 

times, then only the first impact shall be used. If the test threat bounced out of the 

initial hole, then the test threat shall be manually reinserted into that initial hole 

until it fits snugly but is not forced beyond this point. 

9.5.2.4. For blade test threats, a measurement of the cut length on the test item wear face

shall be taken before reinsertion of the blade; this measurement is then repeated 

after the reinsertion to ensure that the test threat was not inserted further than the 

original depth. 

9.6. Preparation of Test Items

9.6.1. The intended stab locations shall be clearly marked on each test item. The intended 

stab location shall satisfy the fair hit requirements for impact location and spacing.

9.6.1.1. A template shall be used to mark the intended stab impact locations.
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9.6.2. The 0° rotational angle shall be marked from neck to waist vertically, in relation to 

the orientation of the blade strike.

9.6.3. All test items shall be stored at controlled ambient for a minimum of 12 hours prior 

to conditioning by submersion.

9.6.4. Calibration trials of the drop tower apparatus shall be conducted to confirm strike 

energies.

9.6.5. Before conducting a stab test series, preliminary drop test trials shall be conducted 

to determine the drop heights necessary to produce velocities that correspond to 

the specified impact energies determined at a 6.4 mm (0.25 in) standoff from the 

surface of the test item.

9.7. Preparation of Backing Material and Mounting of Test Items

9.7.1. A backing material pack that complies with the requirements of Annex B shall be 

used.

9.7.2. If a female body armor front panel is being tested, then appliques meeting the 

requirements of Annex G shall be used. The appliques shall be placed in their 

designated locations, aligning the apex of each applique directly behind each apex 

of the test item.

9.7.3. If required, a sheet of PolyartTM paper shall then be placed on top of the backing 

material to act as a witness panel and allow penetration depth measurements to be 

made.

9.7.4. The pre-marked test item shall be placed on top of the witness panel, and both the 

witness panel and the test item shifted such that the intended strike location is 

located over unused sections of the paper and the backing material. The test item

panel shall be smoothed, flattened and secured to the backing material and support 

table using nominally 50-cm (2-in) wide, non-elastic straps. The straps shall be 

held together using hook and loop attachments or other suitable fasteners.

9.7.4.1. Figure 1 details the location of the straps. The placement of the straps shall be a 

minimum of 127 mm (5 in) apart, measured from the inner boundary of the strap, 

and a maximum of 178 mm (7 in) apart such that they do not interfere with the 

impact point on the test item. The straps shall securely hold the test item in place 

without any visible compression of the backing materials.

9.7.4.2. When required, the test item shall be rotated to achieve the appropriate rotational 

angle.

9.7.4.3. When required, the test item shall be tilted to achieve the appropriate angle of 

incidence.
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9.8. Test Details

9.8.1. Table 4 details the test series for planar test items, including the sequence, panel 

front or back, test threat, angles, energy number of impacts and panel rotational 

angle. 

9.8.1.1. See Annex F for diagrams showing impact locations for planar test items. Impact 

location A shall always be the geometric center of the panel; impact locations B, 

C, D and E shall be located as shown in the figures; and other impacts shall be 

distributed in the unlabeled locations. 

9.8.1.2. For testing with the SP test threat, at least one perpendicular impact per test item 

shall be within 38 mm (1.5 in) from the edge.

9.8.1.3. The 0° angle shall be indicated by the test lab on the test item from neck to waist 

vertically.

9.8.2. Table 5 details the test series for nonplanar female test items, front panels only. If 

testing of back panels is required, the details of Table 4 shall apply. 

9.8.2.1. See Annex G for details on appliques and diagrams showing the locations for the 

impacts for female nonplanar front panels. 

9.8.2.2. For testing with the SP test threat, at least one perpendicular impact per test item 

shall be within 38 mm (1.5 in) from the edge.

9.8.2.3. The 0° angle shall be indicated by the test lab on the test item from neck to waist 

vertically.

Figure 1. Acceptable Strapping Method
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Table 4. Test Series for Planar Test Items

Panel 

# Panel Test Threat

Angle of 

Incidence Energy # Impacts

Impact

Locations 

Panel 

Rotational 

Angle*

1 Front 

P1

0 ± 5° Primary 

E1

2 A, B 0° ± 15°

P1 2 C, D 45° ± 15°

P1 2 E, F 90° ± 15°

P1 2 G, H Any angle

P1 45° ± 5° Primary 

E1 2 I, J 2 angles > 30° different

2 Back

P1

0 ± 5° Primary 

E1

2 A, B 0° ± 15°

P1 2 C, D 45° ± 15°

P1 2 E, F 90° ± 15°

P1 2 G, H Any angle

P1

0 ± 5° Overtest 

E2

1 I 0° ± 15°

P1 1 J 45° ± 15°

P1 1 K 90° ± 15°

P1 1 L Any angle

3 Front 

P2

0 ± 5° Primary 

E1

2 A, B 0° ± 15°

P2 2 C, D 45° ± 15°

P2 2 E, F 90° ± 15°

P2 2 G, H Any angle

P2 45° ± 5° Primary 

E1 2 I, J 2 angles > 30° different

4 Back

P2

0 ± 5° Primary 

E1

2 A, B 0° ± 15°

P2 2 C, D 45° ± 15°

P2 2 E, F 90° ± 15°

P2 2 G, H Any angle

P2

0 ± 5° Overtest 

E2

1 I 0° ± 15°

P2 1 J 45° ± 15°

P2 1 K 90° ± 15°

P2 1 L Any angle

5 Front 

SP 0 ± 5° Primary

E1 8 

A, B, C, 

D, E, F, 

G, H

N/A

SP 45° ± 5° Primary

E1 2 I, J 2 angles > 30° different

6 Back

SP 0 ± 5° Primary

E1 8 

A, B, C, 

D, E, F, 

G, H

N/A

SP 0 ± 5° Overtest

E2 4 I, J, K, L N/A
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Table 5. Test Series for Nonplanar Female Test Items: Front Panels Only 

Panel # Applique 

(Cup Size)

Test 

Threat Energy Angle of Incidence

Location on 

Panel

1 A2 (B-cup) 

P1 Primary E1 0 ± 5 A

P1 Overtest E2 0 ± 5 B

S1 Primary E1 0 ± 5 C

S1 Overtest E2 0 ± 5 D

P1 Primary E1 45 ± 5 E

S1 Primary E1 45 ± 5 F

2 A2 (B-cup) 

P1 Primary E1 0 ± 5 A

P1 Overtest E2 0 ± 5 B

S1 Primary E1 0 ± 5 C

S1 Overtest E2 0 ± 5 D

P1 Primary E1 45 ± 5 E

S1 Primary E1 45 ± 5 F

3 A5 (E-cup)

P1 Primary E1 0 ± 5 A

P1 Overtest E2 0 ± 5 B

S1 Primary E1 0 ± 5 C

S1 Overtest E2 0 ± 5 D

P1 Primary E1 45 ± 5 E

S1 Primary E1 45 ± 5 F

4 A5 (E-cup)

P1 Primary E1 0 ± 5 A

P1 Overtest E2 0 ± 5 B

S1 Primary E1 0 ± 5 C

S1 Overtest E2 0 ± 5 D

P1 Primary E1 45 ± 5 E

S1 Primary E1 45 ± 5 F

5 A2 (B-cup) 

Spike Primary E1 0 ± 5 G

Spike Overtest E2 0 ± 5 H

Spike Primary E1 0 ± 5 G2

Spike Overtest E2 0 ± 5 H2

Spike Primary E1 45 ± 5 I

Spike Primary E1 45 ± 5 I2

6 A5 (E-cup)

Spike Primary E1 0 ± 5 G

Spike Overtest E2 0 ± 5 H

Spike Primary E1 0 ± 5 G2

Spike Overtest E2 0 ± 5 H2

Spike Primary E1 45 ± 5 I

Spike Primary E1 45 ± 5 I2
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10. Stab Test Procedure

10.1. Stab testing requires a stab test apparatus meeting the requirements of Annex B. 

10.2. Insert the drop mass, including test threat, into the bottom end of the guided drop 

assembly in its proper orientation. Attach the drop mass to the hoist. 

10.2.1. For tests requiring 45° angle of incidence, the cutting edge of the blade shall face 

the test item. 

10.3. Adjust the hoist so that the drop mass is exposed from the drop tube by 210 ± 13 mm 

(8.25 ± 0.50 in) as measured vertically from the bottom edge of the drop tube to the 

leading edge of the polymer portion of the sabot. 

10.4. Place the test item on the backing material and position this assembly beneath the drop 

mass. 

10.5. Adjust the height of the articulating table such that the tip of the test threat is within 25 

mm (1 in) of the surface of the test item. 

10.6. Horizontally position the test item below the drop tube such that the test threat will 

strike at the intended impact location. 

10.7. Raise the drop mass to the proper height determined in Section 10.3 so that it will 

strike with the specified energy.

10.8. Initialize the velocity measurement instrumentation in preparation for making a 

measurement. 

10.9. Release the drop mass.

10.10. For each impact, record penetration depth, kinetic energy, impact location, angle of 

incidence, rotation angle and other required data. 

10.11. Repeat the above steps until all required impacts on all test items are complete.

11. Test Report

11.1. The test laboratory shall develop a test report that meets the requirements of ISO/IEC 

17025 and the referenced ASTM standards. 

11.2. All data and required calculated values shall be included in the test report. 
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Annex A (Mandatory): Test Threat Drawings and Requirements

Drawings for Test Threats

The drawings below detail the specifications required for the commercial threat test items: P1, 

S1 and SP1. 

Figure A.1. P1 Single-edged Blade
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Figure A.2. S1 Double-edged Blade
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Figure A.3. SP1 Spike 
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The drawings below detail the specifications required for the improvised threat test items: T1, 

T2 and T3. 

Figure A.4. T1 Improvised Single-edged Blade
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Figure A.5. T2 Improvised Double-edged Blade
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Figure A.6. T3 Improvised Spike 

Test Threat Requirements

1. Each test threat shall be inspected to ensure that it meets the requirements of the respective 

engineering drawings and that the overall finish is clean and free from rough edges. 

2. Each commercial test threat shall be subjected to a tip sharpness test and shall be 

considered acceptable for stab testing if it produces a “hardness” value of between -50 and 

-150 on the Rockwell C scale in the following modified Rockwell hardness tip sharpness 

test: 

2.1. The standard indenter shall be replaced with an adapter that will hold the test threat. 

2.2. The machine shall be preset to give minor and major loads of 3 kg (6.61 lb) and 5 kg 

(11.0 lb) respectively, to produce a total load of 8 kg (17.61 lb). 

2.3. The sample block to be indented shall be a small flat block of 99.997 % nearly pure 

aluminum at least 5 mm (0.197 in) thick. 

2.4. The test threat shall first be wiped with a clean dry cotton cloth to remove any traces 

of lubricant and then installed in the holder adapter. 

2.5. The test threat tip sharpness shall then be measured by applying the load to the blade 

or spike tip into the aluminum block and recording the reading from the Rockwell C 

scale.
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Note: These are not actual Rockwell hardness values because of the modifications to 

the machine and test procedure. As an alternative means of assessing the tip sharpness, 

the range of Rockwell C values are expressed in terms of indentation depth produced 

by the major load application, and correspond to indentation depths in the aluminum 

test block of 0.30 mm (0.012 in) and 0.50 mm (0.020 in), for “hardness” values of -50 

and -150 respectively. See Table A.1 listing relating the hardness values to indentation 

depth (D). 

3. Each improvised test threat shall meet the dimension and material specifications in the 

table below. 

Table A.1. Conversion of HRC Values to Indentation Values

HRC D 

(mm) HRC D (mm) HRC D (mm) HRC D (mm) HRC D (mm)

-160 0.52 -130 0.46 -100 0.40 -70 0.34 -40 0.28

-150 0.50 -120 0.44 -90 0.38 -60 0.32 -30 0.26

-140 0.48 -110 0.42 -80 0.36 -50 0.30 -20 0.24

Table A.2. T1 Threat Specifications

Description Unit Lower 

tolerance Nominal Upper tolerance

Length Inch 4.37 4.38 4.39

Width Inch 0.779 0.781 0.783

Tip plan angle Deg 19.5 20.0 20.5

Tip flat width Inch 0.007 0.009 0.011

Tip flat condition - - No burrs -

Tip crest condition - - No burrs -

Grind angle Deg 39.5 40.0 40.5

Grind surface finish Ra 16 - 32

Edge flat width Inch 0.02 0.021 0.022

Edge flat surface finish Ra 16 - 32

Body long edge surface finish Ra 16 - 32

Body short edge surface finish Ra 16 - 32

Body underside surface finish Ra 16 - 32

Body upper-side surface finish Ra 16 - 32

Body flatness Inch 0 - 0.002

Body thickness Inch 0.107 0.109 0.111

Hardness RB 50 - 55
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Table A.3. T2 Threat Specifications

Description Unit Lower 

tolerance Nominal Upper tolerance

Length Inch 4.79 4.80 4.81

Width Inch 0.779 0.781 0.783

Tip plan angle Deg 29.5 30.0 30.5

Tip plan angle symmetry Deg 14.5 15.0 15.5

Tip flat width Inch 0.009 0.01 0.011

Tip flat condition - - No burrs -

Tip crest condition - - No burrs -

Bevel included angle Deg 59.5 60.0 60.5

Grind surface finish Ra 16 - 32

Edge flat width Inch 0.009 0.010 0.011

Edge flat surface finish Ra 16 - 32

Body long edge surface finish Ra 16 - 32

Body short edge surface finish Ra 16 - 32

Body underside surface finish Ra 16 - 32

Body upperside surface finish Ra 16 - 32

Body flatness Inch 0 - 0.002

Body thickness Inch 0.123 0.125 0.127

Hardness RB 75 - 80

Table A.4. T3 Threat Specifications 

Description Unit Lower 

tolerance Nominal Upper tolerance

Length Inch 3.90 3.91 3.92

Shaft body diameter Inch 0.124 0.125 .0126

Tip cone angle Deg 12.0 12.5 13

Tip flat width Inch 0.021 0.022 0.023

Tip flat condition - - No burrs -

Tip cone surface finish Ra 16 - 32

Shaft body surface finish Ra 16 - 32

Shaft body concentricity Inch 0 - 0.002

Shaft body flatness Inch 0 - 0.002

Shaft body end chamfer Present

Hardness Rb 65 - 70
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Annex B (Mandatory): Stab Test Apparatus, Requirements and Setup

1. The stab test apparatus consists of a guided drop assembly, velocity measurement 

instrumentation, an articulating table, a drop mass, test threat, composite backing material 

and test item strapping. See Figure B.1 for an overview of the stab test apparatus with the 

drop mass and test threat fully deployed. 

Note: The composite backing material and test threats are consumable materials that 

require replacement.

2. The guided drop assembly facilitates the delivery of the test threat to the surface of the test 

item with specific orientation and velocity. The test threat is attached to a drop mass to 

ensure the test threat impacts the test item at the required energy. The guided drop 

assembly consists of a rigid tube or equivalent, affixed vertically to the laboratory wall or 

ceiling, and a mechanism for raising and releasing the drop mass from a specified height. 

On release, the drop mass falls freely, delivering the test threat to the strike face of the test 

item, and the guided drop tube prevents rotation about the vertical axis of the drop mass. 

The test item is held in place, by strapping, on composite backing material mounted atop 

an articulating table that allows the test item to be angled with respect to the test threat.

The velocity measuring instrument measures the velocity at which the test threat falls.

Figure B.1. Diagram of Stab Test Apparatus
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3. Guided Drop Assembly 

3.1. The guided drop assembly consists of a rigid tube or equivalent, affixed vertically to 

the laboratory wall or ceiling, and a hoist for raising and releasing the drop mass from 

a specified height.

3.2. In order to meet the energy requirements for this test, the drop distance ranges up to 

approximately 4.25 m (14 ft).

3.3. Velocity Measurement Equipment 

3.3.1. A suitable method of accurately measuring the velocity of the drop mass within the 

velocity measurement zone shall be employed. 

3.3.2. The measuring equipment shall measure the velocity to an accuracy of ± 0.05 m/s 

(± 0.16 ft/s) or better. 

3.3.3. The velocity gates shall be positioned to measure the velocity of the drop mass 

when the leading edge of the polymer portion of the sabot is 210 ± 13 mm (8.25 ± 

0.50 in) below the bottom edge of the drop tube. 

4. Composite Backing Material: 

4.1. A pack of composite backing material shall be used. The composite backing material 

pack shall measure 60 cm ± 1 cm (24 in ±1/3 in) in length and 60 cm ± 1 cm (24 in ± 

1/3 in) in width. Adjustments in length and width may be made to accommodate 

smaller test items; however, the minimum permitted size of the backing material pack 

is 38 cm (15 in) by 30 cm (12 in). 

4.2. The components of the backing material pack shall consist of layers of materials (from 

the strike face down) as shown in Figure B.2, and the materials shall be as specified 

below and in Tables B.1, B.2 and B.3: 

4.3. Neoprene: 

4.3.1. Density measurements shall be conducted according to ASTM D3575 on 

cylindrical samples of 50 mm (1.97 in) diameter prepared using the same hole saw 

for cutting dampers. 

4.3.2. Thickness shall be measured using calipers (or other suitable measurement 

instrument) accurate to ± 0.5 mm (0.02 in) or better. 

4.3.3. Compression deflection measurements shall be conducted on four layers of 

neoprene according to ASTM D3575 and in the cylindrical geometry for the 

dampers.

4.3.4. Shore hardness measurements shall be conducted on the polyethylene without the 

skin to confirm the surface hardness is consistent between tests. 

4.3.5. The durometer shall be a type OO durometer.

4.4. Plastazote: 

4.4.1. A single layer of closed-cell low-density plastazote crosslinked polyethylene foam, 
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4.4.2. Density measurements shall be conducted, according to ASTM D4819 on 

cylindrical samples of 50 mm (1.97 in) diameter prepared using the same hole saw 

for cutting dampers.

4.4.3. Thickness shall be measured using calipers or a micrometer accurate to ± 0.5mm 

or better. The polyethylene shall be ordered with the thick skin removed to achieve 

the specified thickness. 

4.4.4. Compression deflection measurements shall be conducted on a single layer of 

polyethylene according to ASTM D3575 and in the cylindrical geometry for the 

dampers.

4.4.5. Shore hardness measurements shall be conducted on the polyethylene without the 

skin to confirm the surface hardness is consistent between tests. 

4.4.6. The durometer shall be a type OO durometer. 

4.5. Natural rubber sheet: 

4.5.1. Shore hardness measurements shall be conducted on the surface of the natural 

rubber. 

4.5.2. The durometer shall be a type A durometer.

Table B.1. Neoprene (EPDM/SBR) Specification

 Test Method Requirement 

Color N/A Black

Type N/A Closed

Standard Specification ASTM D1056 2A3

Density (kg/m3) ASTM D3575#

 150 ± 15 

Thickness (mm) N/A 6 ± 0.5 

10%: 47 ± 15 

Compression Deflection (kPa), % strain ASTM D1056 25%: 73 ± 13 

50%: 162 ± 10 

Shore Hardness [OO Scale] ASTM D2240 60 ± 5 

Figure B.2. Composite Backing Material Layers
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#

 No ASTM density standard is identified for sponge or expanded rubber; it is recommended 

to use the method prescribed for polyolefin foam. Samples should be cylindrical with the 

same diameter as the polyethylene damping discs.

Table B.2. Polyethylene Specification

 Test Method Requirement

Color N/A Black

Type N/A Closed

Standard Specification ASTM D4819 D4819 Type I - B4

Density (kg/m3) ASTM D3575 32 ± 2 

Thickness (mm) N/A 28 ± 2 (no skin) 

 10%: 40 ± 10 

Compression Deflection (kPa) ASTM D3575 25%: 55 ± 10 

50%: 125 ± 10 

Shore Hardness [OO Scale] ASTM D2240 60 ± 3 

Table B.3. Rubber Specification

Test Method Requirement

Color N/A Black

Type N/A Natural

Shore Hardness [A Scale] ASTM D2240 50 ± 5

Thickness (mm) N/A 6 ± 0.5 

4.6. Composite Backing Material Acceptance Criteria

4.6.1. The individual materials shall meet the requirements stated in Tables B.1, B.2, and 

B.3, prior to use in testing. 

4.6.2. Where test items have a pre-formed curve that is not considered a bust form, it 

may not be possible for the rear face of the test item to lie in close contact with the 

surface of the backing material. If this occurs, then the following should be 

attempted in the order described: 

4.6.3. If the armor design permits, the test item shall be flattened so that the curved 

portions of the armor make good contact with the backing material.

4.6.4. If it is still not possible to achieve good contact between the test item and the 

backing material, then smaller pieces of the neoprene backing material shall be cut 

and then stacked together to make good contact with the tight curvature of the test 

item. 

4.6.5. Composite Backing Material Acceptance Test 1

4.6.6. The backing materials shall be conditioned at controlled ambient. 

4.6.7. The pack shall be assembled in the correct order as described above and placed on 

a rigid surface. 
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4.6.8. The pack shall be strapped to the rigid surface, under tension similar to testing, to 

reduce any air gaps between the material layers or between the pack and the rigid 

surface. 

4.6.9. A 1.042 kg (2.297 lb) spherical steel ball shall then be dropped from a vertical 

height of 1,500 mm ± 15 mm (59 in ± 0.59 in) above the surface of the pack.

4.6.10. The height of the rebound shall be measured.

4.6.11. The point of impact of the steel sphere on the backing material shall be marked.

4.6.12. Composite Backing Material Acceptance Criteria 1

4.6.13. The height of rebound achieved from each of two drops shall be 475 mm ± 76 mm 

(18.7 in ± 3.0 in). The marked points of impact of the steel sphere on the backing 

material shall not be positioned immediately below the impact point for any of the 

stab tests. The center of the impacts shall be spaced at least 51 mm (2 in) apart 

from each other and 51 mm (2 in) from the edge.

4.6.14. The backing material shall be replaced when it is no longer possible to conduct a 

strike greater than 51 mm (2 in) from the edge and from previous strikes.

4.7. Female Armor Backing Material

4.7.1. The appliques for testing female armor shall be formed using Roma Plastilina No.1 

as described in ASTM E3086, Standard Practice for Creating Appliques for Use in 

Testing of Nonplanar Soft Body Armor Designed for Females.

4.8. Drop Mass

4.8.1. The drop mass consists of the following components: 

4.8.1.1. A test threat, as defined in Annex A.

4.8.1.2. A sabot designed and built according to the drawings available from the NIJ 

Compliance Testing Program. 

4.8.1.3. Two damping disks

4.8.2. Each damping disk shall be made from the same closed cell polyethylene foam 

used in the composite backing material. 

4.8.2.1. Each disk shall be 28 mm ± 1 mm (1.1 in ± 0.04 in) thick and 50 mm (1.97 in) 

diameter and should be cut using a steel hole saw 50 mm (1.97 in) diameter, 

without the center guiding bit. The hole saw shall have a smooth bore and a knife 

edge for cutting, and distilled water should be used as a cooling lubricant.

4.8.2.2. The disks shall be allowed to dry for a minimum of 24 hours prior to use in stab 

testing.

4.8.3. The drop mass shall securely hold the test knife blade or spike with at least 81 mm 

(3.2 in) of the blade or spike length exposed. The shape of the lower surface of the 

drop mass shall permit at least 30 mm (1.2 in) of penetration to occur while 

striking the test item at a 45° angle of incidence. 

4.8.4. Assembly of Drop Mass
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4.8.4.1. Two damping disks shall be installed in the nylon body of the upper portion of the 

sabot. 

4.8.4.1.1. For damping disks that are used for commercial threat armor testing and drop tests 

at less than 65 J (47.9 ft·lbf), they shall be replaced after being subjected to no 

more than 1 seating drop and 10 drop tests. 

4.8.4.1.2. For damping disks that are used for improvised threat testing at 65 J (47.9 ft·lbf) or 

greater, they shall be subjected to no more than one seating drop and five drop 

tests. 

4.8.5. Five minutes shall elapse between drops to allow the damping disks to recover. 

The lower portion of the sabot should not exhibit slack (e.g., no resistance felt 

when moving lower mass up into upper mass) prior to loading threat. If the 

dampers do not recover within the five-minute period, the disks shall be replaced. 

4.8.6. Once the damping disks have reached their drop limit (5 or 10 drops respectively), 

they shall be discarded. 

4.8.6.1. After installation of the damping disks, the lower drop mass shall be inserted into 

the upper mass, and the damping disks shall be compressed 6mm +/- 2mm. 

4.8.6.2. Prior to first test drop and after every change of damping disk; an initial damper 

seating drop must be made onto an armor panel with conditioned backing material 

and test threat present. The drop must be at the same energy as the intended test 

energy. A threat blade must be used, although an old blade is permissible. This 

drop is to be performed prior to compliance drop tests being conducted and every 

time the dampers are changed during the test process. The test should be in an 

unused section of the test armor and marked accordingly to identify it as a damper 

seating test. A separate/spare armor may be used. 

4.8.7. A recovery period of at least 5 minutes is required between each drop. 

4.9. Installation of Test Threat Into Drop Mass 

4.9.1. A new test threat shall be used for each test strike. 

4.9.2. The specified test threat shall be affixed to the drop mass and the assembly shall be 

weighed to the nearest gram. The mass measurement method shall have an 

accuracy of ± 1 g (± 0.002 lb) or less. 

4.10. Witness Panel

4.10.1. The witness panel shall be panel PolyartTM paper having a basis weight of 140 g/m2

and a thickness of 0.178 mm (7 mil). Penetration measurements shall be taken from 

the cut in the witness paper. 
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Annex C (Mandatory): Equipment and Procedure for Conditioning Soft Armor by 

Submersion 

Equipment

The armor submersion equipment shall consist of a water bath sufficiently sized to allow at 

least one test item of the largest template size to hang vertically, without any folds or bends, 

with the top edge of the test item at least 102 mm (4 in) below the surface of the water, and 

with at least 51 mm (2 in) clearance around the test item. 

The water in the bath shall be clean and shall be either potable tap or demineralized water. 

The water shall be replaced any time there are visible impurities in the water. The water 

temperature shall be 21 °C + 3 °C/-6 °C (70 °F + 5 °F/-10 °F). 

Procedure

Each test item shall be hung vertically in the water bath for 30 min (+ 5 min/- 0 min) with the 

top edge of the test item positioned 100 mm ± 25 mm (4 in ± 1 in) below the water surface

and maintaining at least 51 mm (2 in) clearance around the test item. For test items that are 

buoyant, weights shall be attached to the bottom edge with clothes pins or similar clips to 

allow the test item to hang vertically. After removing the test item from the water, it shall be 

hung vertically to drip dry for 10 min (+ 5 min/- 0 min) before mounting on 

the backing material for stab testing. 
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Annex D (Mandatory): Template for Test Item Size

Note on sizing template: The red outline below represents the maximum dimensions for either 

the front or the back panel. The blue outline below represents the minimum dimensions for 

either the front or the back panel. The dashed, blue line represents the maximum scoop 

allowed for the neck scoop for the front panel only. It is a common misconception that the red 

outline represents the back panel and the blue outline represents the front panel. 
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Annex E (Mandatory): Test Item Label Requirements and Testing

Test Item Label Content Requirements

The label shall be permanently attached to the face of the panel. The label shall contain the 

following information (an example is provided in Figure E.1): 

• Name, registered trademark or other identification 

of the supplier. 

• The rated level of protection and reference to this 

edition of the standard (e.g., NIJ Commercial 

protection level in accordance with NIJ Standard0115.01).

• A test ID number or model designation that 

uniquely identifies the armor design for testing 

purposes. 

• The test item template size.

• A number or serial number that uniquely identifies 

each test item. 

• Location of manufacture. 

• The date of manufacture.

• Identification of the proper orientation of the stab 

panel (i.e., strike face or wear face). 

• A warning in larger type than the rest of the type on 

the label that clearly emphasizes the warning, 

stating that the stab panel is a test item that has not 

yet been demonstrated to provide stab resistance 

and that the armor panel is not intended to be worn. 

Printing color changes are acceptable but cannot be 

substituted for the type size requirement herein. 

Test Item Label Permanency and Durability

1. References

1.1. ASTM E2771, Terminology for Homeland Security Applications. West 

Conshohocken, PA: ASTM International.

1.2. ASTM D5264, Practice for Abrasion Resistance of Printed Materials by the 

Sutherland Rub Test. West Conshohocken, PA: ASTM International.

2. Terms and Definitions 

Figure E1. Example Test Item Label
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2.1. For terminology not defined in this annex, the definitions found in ASTM D5264 and 

ASTM E2771 apply.

2.2. Label, n – A material applied to a product and containing information about the 

product.

2.3. Label assembly, n – The label itself and any clear plastic laminate that will be used to 

protect the label.

2.4. Label system, n – The label assembly and the substrate to which it is applied.

2.5. Substrate, n – The material identical to the external surface of the production body 

armor to which the label will be affixed. In soft armor, this will typically be the 

ballistic panel cover material. In some hard armors, the substrate will be the plate 

material itself. In other hard armors, the substrate will be the plate wrap material or the 

“sprayed-on liner” covering material. 

2.6. Test item, n – A single article intended for testing (ASTM E2771). For this annex, the 

test item shall be the labeling system being evaluated. This system includes the label 

itself, the substrate the label adheres to and any clear plastic laminate intended to 

protect the label. See Figure E.2 for a graphic of the labeling system.

3. Test Items

3.1. The test item is the labeling system being evaluated. This labeling system shall match 

(in materials and manner of construction) the labeling system intended for use on the 

finished product. 

3.1.1. To facilitate testing, the label assembly on the test items shall be affixed such that the 

long edge of the label assembly is near the edge of the substrate, as shown in Figure 

E.2. If a clear laminate is present in the label assembly, it shall not extend more than 

0.5 in (13 mm) beyond the edge of the label at this edge. The label itself shall be less 

than 0.75 in (19 mm) away from and parallel to the same edge of the substrate. 

3.2. Special considerations for hard armor systems

3.2.1. All substrate systems shall be nominally flat. 

3.2.2. If the label substrate material is not a stand-alone material (e.g., spray liner or fabric 

wrap), then the manufacturer shall submit test items with representative substrates 

applied to a nominally planar surface (e.g., plastic, steel or wood). The surface finish 

of this material shall be representative of the surface finish that will be present in the 

finished product.

3.2.3. A total of 10 test items shall be submitted for testing.

4. Visual Examination of Test Items

4.1. Visually examine each test item for imperfections. Imperfections include areas along 

the edge of the label or clear plastic laminate that are not in contact with the substrate 

or areas of the clear plastic laminate that are not in contact with the label. 

4.2. Document any observed imperfections.
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5. Resistance to Peeling Test

5.1. Quantity of Test Items

5.1.1. Two new test items are required.

5.2. Equipment and Materials 

5.3. Packaging tape: Nominally 2-in wide, clear polypropylene tape with acrylic adhesive, 

adhesion to steel rating of 32 to 35 oz/in (36 to 39 g/mm). 

5.4. Procedure 

5.4.1. Place the test item on a smooth, flat surface.

5.4.2. Adhere packaging tape lengthwise to the top surface of the label assembly. The 

adhered section must extend from at least the center of the label itself to approximately 

0.25 to 0.5 in (6 to 13 mm) beyond a side edge of the label assembly. Form a “pull 

tab” by extending the length of the tape beyond this adhered section, doubling the tape 

back on itself. 

5.4.3. After waiting 60 seconds, hold the substrate down and use the pull tab while pulling 

the packing tape to remove the packing tape from the test item. 

5.4.4. Document if any portion of the label assembly was removed from the substrate. 

5.4.5. The label has failed this test if any of the label assembly is removed from the substrate.

Figure E.2. Graphic of Labeling System
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6. Ink Permanency Test

6.1. Quantity of Test Items

6.1.1. Four new test items are required.

6.2. Equipment and Materials

6.2.1. A Sutherland Ink Rub Tester (SIRT) shall be used, with a test weight having mass of 4 

lb ± 0.18 oz (1.81 kg ± 5 g), as specified in ASTM D5264. The speed during testing 

shall be 42 cycles per minute.

6.2.2. The abradant shall be white nylon fabric, 200 Denier, uncoated.

6.2.3. Three challenge fluids are used.

• Water: nominally tap water

• Isopropyl alcohol: nominally 70% by volume commonly available

• Water, oil, soap combination with the following formulation: 

o 1 fl oz (30 ml) dish soap

o 1 fl oz (30 ml) mineral oil 

o 18 fl oz water (532 ml) 

6.2.4. Shake vigorously for a minimum of 30 seconds to mix well before every application.

6.2.5. This test shall be conducted on a new, dry test item and then repeated on new test 

items with each challenge fluid.

6.3. Procedure

6.3.1. Place a test item onto the SIRT such that: 

1) The long edge of the label assembly is parallel to the face of the ink rub testing 

apparatus.

2) The narrow edge of the test is closest to the face of the SIRT if the test item is 

asymmetrical to meet the requirements of Section 3.3.1.1.

3) The centerline of the label assembly is aligned with the nominal center of the 

sweep of the test weight. 

4) The test item is secured in place and unable to move when the test is initiated. 

6.3.2. Place the abradant nylon into the holders on the base of the test weight supplied with 

the SIRT. Ensure that there are no folds or creases present in the nylon fabric and that 

it is pulled tight enough to prevent folds and creases from forming during testing. 

6.3.3. Apply the challenge fluid to the abradant (when a challenge fluid is being used). 

6.3.4. Place the test weight and abradant assembly onto the SIRT. 

6.3.5. Run the SIRT for 2,000 cycles.

6.3.6. When a challenge fluid is being used, reapply it every 500 ± 100 cycles. 

6.3.7. Inspect the labels at the end of the test to check for damage to the label. 

Note: the evaluation is being performed on the label itself and not on any component 

intended to protect the label such as a clear plastic laminate coating.
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6.3.8. If any individual character is rendered completely illegible by the test, then the label 

system has failed the test.

6.3.9. The label has failed this test if one or more characters become damaged through the 

course of the testing described above. The label has not failed if the characters on the 

label remain intact despite significant damage occurring to the label assembly.

7. Edge of Label Challenge and Ink Permanency Test

7.1. Quantity of Test Items

7.1.1. Four new test items are required.

7.2. Equipment and Materials 

7.2.1. The equipment and materials shall be the same as specified in Section 5.

7.2.2. This test shall be conducted on a new dry test item and then repeated on new test items 

with each challenge fluid. 

7.3. Procedure 

7.3.1. Place a test item onto the SIRT such that: 

1) The long edge of the label assembly is parallel to the face of the ink rub testing 

apparatus.

2) The narrow edge of the test item is closest to the face of the SIRT if the test item is 

asymmetrical to meet the requirements of Section 3.3.1.1. 

3) The edge of the label itself is aligned with the nominal center of the sweep of the 

test weight. Note: this creates a scenario in which the edge of the label is being 

challenged, but the edge of any clear plastic laminating material is only being 

challenged if it is within the sweep of the test weight.

4) The test item is secured in place and unable to move when the test is initiated. 

7.3.2. Place the abradant nylon into the holders on the base of the test weight supplied with 

the SIRT. Ensure that the nylon abradant is well positioned to prevent folds and 

creases from forming during testing. 

7.3.3. Place the test weight and abradant assembly onto the SIRT. 

7.3.4. Apply the challenge fluid (when one is being used in this test). 

7.3.5. Run the SIRT for 2000 cycles. 

7.3.6. When a challenge fluid is being used, reapply it every 500 ± 100 cycles. 

7.3.7. Inspect the labels at the end of the test to check for damage to the label.

7.3.8. The label has failed this test if one or more characters become damaged. The label has 

not failed if the characters on the label remain intact despite significant damage 

occurring to the label assembly. 

8. Test Report 

8.1. The results from the label test and any relevant observations shall be included in the 

body armor test report.
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Annex F (Mandatory): Diagrams showing impact locations for planar test items 

Figures F.1 and F.2 show the impact locations for each test item. 

Figure F.1. Planar Front Panel Impact Locations

Figure F.2. Planar Back Panel Impact Locations
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Annex G (Mandatory): Soft Armor Designed for Female Wearers

Nonplanar armor designed for female wearers is tested using the same apparatus as used for 

planar test items; however, appliques are used to support the armor during testing. For 

information on creating appliques for use in testing nonplanar armor designed for females, 

please refer to ASTM E3086-17, Standard Practice for Creating Appliques for Use in Testing 

of Nonplanar Soft Body Armor Designed for Females. 

Appliques shall be created in accordance with ASTM E3086-17 section 5 through section 8.1 

inclusive. In lieu of sections 8.2 & 8.3, place the appliques on the foam backing material, 

aligned horizontally with the apex of each bust positioned to reflect the distance created 

between bust apexes on the wear face of the armor being tested. On completion of the testing, 

the top layer of neoprene must be removed and discarded. 

Figures G.1 – G.6 show the impact locations for each test item.

Figure G.1. Impact Locations for Panel 1
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Figure G.2. Impact Locations for Panel 2

Figure G.3. Impact Locations for Panel 3
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Figure G.4. Impact Locations for Panel 4

Figure G.5. Impact Locations for Panel 5
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Figure G.6. Impact Locations for Panel 6
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Annex H (Mandatory): Conversion Tables for Penetration Depth