for Military or Law Enforcement Body Armor

Automated process to cover body armor plates to SAPI/ESAPI
Save time…Save Money…Reduce Liabilities

ARMA-Guard is a unique blend of urethane film that provides the correct
balance of chemical and UV resistance. TPU is abrasion resistant and has
been used to line inside of gas tanks. This system has been DOD tested
and approved.

TPU sheets are provided pre-printed with registration holes to align print to
body armor plate during vacuum forming process.

Each side of the plate is vacuumed formed in an automated machine with
PLC controls for time and temperature events. TPU matrix is razor
trimmed, then plate edges are seamed in a purpose built thermal press.

The absolute best label technology is a TPU label bonded to a TPU Spall
cover. We call it “Mold-IN ” technology as the TPU label becomes part of
the Spall cover.
No edge pick – No removal of our ARMA-ID TPU Labels.

Labels are bonded to TPU Spall cover with a thermal press built to
accommodate the multi-curve plate design. A template locates the plate in
the press base and a curved heat platen bonds the TPU label via heat and
light pressure.

ARMA-Guard is more than a material offering. It is a system to Spall cover
a body armor plate using automated processes for covering, edge seaming
and label attachment.




  • Zero weight gain from liquids, dirt and other elements
  • High Abrasion resistance
  • Excellent low-temperature and impact strength
  • Resilience to oils, greases, salt water, JP-8
  • Remains flexible over a wide temperature range
  • Robust weather and high-energy radiation resistance
  • High elasticity across the entire hardness range
  • Anti-slip feature
  • Wide range of colors and Patterns
  • High UV Resistance
  • Cleans easily – non staining
  • Material/color consistency
  • Lower weight
  • Hydrophobic material
  • Low microbe transmission
  • Not effected by humidity changes
  • No seam separation
  • Better ink adhesion


  • Increased productivity
  • Enabled JIT Processes
  • Reduced labor
  • Reduced CTS
  • Controlled Cost
  • No edge burn
  • Minimized rejection
  • Minimized rework
  • Field repairable
  • No shelf life
  • Automated hermetic seaming
  • No folding and soldering
  • No VOC’s
  • Improved label processing
  • Elimination of adhesive drum/pail removal
  • Improved CPK
  • Lower insurance cost


257 East Alamo Drive • Chandler AZ 85225 • Phone: 480-968-6631 • Fax: 480-966-1885

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ARMA-Guard TPU sheets
Textured and printed w/registration holes

THE PROCESS – Vacuum forming:

TPU sheets are placed into a vacuum forming machine using registration pins to align printed TPU sheet to your body armor plate.

We have tested and approved Formech as a very capable vacuum forming machine with state of the art PLC programmable controls for temperature profile, motion control, event timing, vacuum adjustment and safety.

Below is a video of the formech machine and press details.

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THE PROCESS – Edge Seaming:

After each side of the plate is covered – the excess TPU (matrix) is razor trimmed using a razor guide cutter.
Once both front and back sides of the plate are covered – the plate edge is taped and seamed using the edge seamer machine. (Picture below)

THE PROCESS – Label Bonding:

ARMA-ID TPU labels are applied by heat bonding the label to the formed TPU plate using the Label Bonding Press.
(Picture below)

THE PROCESS – Line Production:

Cycle time of 1 min, 20 seconds per finished plate can be achieved using line production similar to the layout pictured below. Note: Should batch processing better suite your work flow, the line layout can be segmented and organized as you see fit.