Understanding NIJ Soft Armor Panel Sizes: What C1 to C5 Really Mean for Buyers
Why Buyers Struggle with Body Armor Sizing
If you’ve ever tried to order soft body armor and found yourself staring at “C2,” “C4,” or “C5” on the NIJ CPL or a test report, you’re not alone. Most buyers assume these are consumer sizes—like Small or XL—but they’re not.
C1–C5 are NIJ (National Institute of Justice) test templates, not retail-size labels. They define the ballistic test panel shapes and sizes used during certification under NIJ Standard-0101.06 (2008) and carried forward into NIJ Standard-0101.07 (2023, with addenda in 2024 and 2025). These templates ensure that manufacturers test their armor on consistent panel configurations to prove performance across the size range of real-world users.
For buyers, this distinction matters. A vest labeled “NIJ Certified” must have production panels that conform to the allowable dimensions and areas based on the C-template(s) originally tested. Understanding what each C size represents helps you verify compliance, coverage, and fit before you buy.
That’s where IntelAlytic and The Armor List work together: IntelAlytic explains the regulatory “why,” while The Armor List provides the verified “what” — the data behind every certified model.
What NIJ Templates Really Control
Tables 12, 13, 14 as shown on page 59 of NIJ 0101.06 standard (https://www.ojp.gov/pdffiles1/nij/223054.pdf)
During certification, manufacturers must test their soft armor models using one or more of the five NIJ templates (C1 through C5). These represent the range of torso sizes found among law enforcement officers and public safety professionals.
Each template specifies defined minimum and maximum dimensions (in inches) for front or back panels, which correspond to approximate surface areas. Testing smaller and larger templates demonstrates that the armor design provides consistent ballistic performance across the manufacturer’s entire size range. Production panels are then restricted to the minimum and maximum areas established in NIJ Standard-0101.06 Tables 12, 13, and 14 (these limits are also implied through template conformance in NIJ Standard-0101.07).
Note: The NIJ defines full torso coverage as: Full torso coverage to be, at a minimum, protection for the front, back, and sides of the upper torso and that the minimum production size of soft armor must be at least 63 sq.in.
Note: Pay Close attention to CTP 2013:03 Limited Coverage Ballistic Resistant Body Armor and CTP 2018:03 Minimum Size Requirement for Limited Coverage Armor
In short:
Panels must not be smaller or larger than the tested template limits.
If the manufacturer tested both C1 and C5, their full production range is unrestricted.
If tested only on C2 and C4, their production sizes must stay between those limits.
This is how certification authorities attempt to prevent “oversized” or “untested” variants from reaching the market — a key compliance safeguard for agency procurement officers.
NIJ Standard 0101.07 Sizing Templates from Appendix E (shown below)
See NIJ Standard 0101.07 for complete details, including the images below from Appendix E - https://www.ojp.gov/pdffiles1/nij/307346.pdf
NIJ C1–C5 Template Reference Chart
NIJ Size Guide C1 to C5 Table 1
Notes:
Surface areas are approximate; actual panels are contoured, not rectangular.
Both front and back panels are measured separately; total vest coverage ≈ is double the per-panel area.
Back panels may be slightly larger to ensure overlap and full torso protection.
Dimensions derived from template figures in NIJ Standard-0101.07 Appendix E; area limits from NIJ Standard-0101.06 Table 12 (NIJ, 2008).
For additional NIJ compliance details, see CJTEC’s guidance on the Compliant Product List.
Mapping End User Sizes (XS – 5XL) to NIJ Templates
Buyers see armor labeled XS through 5XL — but those consumer sizes only describe fit, not ballistic template. The mapping below shows approximate real-world relationships derived from verified manufacturer data in The Armor List (including Armor Express, HighCom, and SafeGuard Armor records).
NIJ Size Guide C1 to C5 Table 2
These ranges provide functional context, not certification authority. Under NIJ rules, a manufacturer’s declared model certification covers only panel areas within the tested range — so if your department orders custom or “long” versions, confirm that they remain inside the certified envelope.
The Armor List Advantage: Verified Data for Smarter Procurement
Even the most experienced agency buyer can’t manually verify hundreds of armor models, materials, and certification claims — that’s where The Armor List comes in.
The Armor List maintains 250,000 + verified data points on ballistic products, companies, and materials, including NIJ test templates, panel areas, and certification details.
Buyers can use its comparison tools to:
Verify panel sizes and NIJ templates before purchase.
Compare coverage areas between models or brands.
Filter by compliance status (NIJ 0101.06 / 0101.07, VPAM, HOSDB).
Check manufacturer identifiers (CAGE, DUNS, UEI) for contract eligibility.
View contract history and test records to ensure traceability.
This level of data validation empowers procurement officers, integrators, and end-users to make confident, defensible decisions — backed by documented compliance.
Visit the The Armor List Database to explore verified NIJ sizing and certification data before your next purchase.
IntelAlytic’s Consulting Perspective: Why Sizing Data Is a Compliance Issue
For public-safety agencies, panel sizing is not just about officer comfort—it is a hard compliance requirement baked into every NIJ certification. NIJ Standard-0101.06 (2008) and NIJ Standard-0101.07 (2023, with Addenda 1 & 2) mandate that every production soft armor panel must fall within the surface-area limits of the C1–C5 template(s) actually tested and listed on the manufacturer’s NIJ certificate.
A panel that measures even slightly outside those limits—whether too small or too large—is no longer covered by the certification, even if the label says “NIJ Certified.” If a federal procurement with FARs applies, this triggers automatic lot rejection under FAR 52.246-2, for suppliers this could even mean a potential removal from the NIJ Compliant Products List (CPL), and—worst case—False Claims Act exposure if the agency accepts and issues non-compliant armor.
IntelAlytic helps agencies and suppliers close this gap with verified traceability systems: mapping every SKU to its tested C-template, aligning measurements with ASTM E2902-12 protocols, and maintaining BA 9000 §7.5.3 lot-level records that support NIJ Follow-up Inspection & Testing (FIT). The result? Procurement decisions backed by real, auditable data—so you buy legally compliant protection, not just labeled compliant.
Custom Panels and Special Fit Requests
For tailored or “long-cut” armor, compliance depends on the measured surface area of each panel:
Measure vertical and horizontal coverage (in inches).
Calculate area (length × width × coverage factor ≈ 0.75 for contours).
Match to the closest NIJ template area.
Confirm with the manufacturer that the model’s NIJ certificate lists coverage including your custom area.
Note: The above is based on an average body size and type and does not factor in unique body size/shape characteristics.
IntelAlytic Sizing Guide estimates for C1 to C5 based on front and back panel width and height measurements in inches (Total equal estimated sq in of coverage per panel)
Accuracy, Fit, and Verified Compliance
Understanding NIJ templates isn’t just a technical detail — it’s the foundation of safe, legal, and transparent armor procurement. By combining IntelAlytic’s compliance expertise with The Armor List’s verified data, buyers can move from confusion to clarity.
Whether you’re evaluating an RFP, validating a shipment, or comparing models, accurate panel-area verification is your best defense against costly procurement errors.
Want your armor brand featured in front of agencies, distributors, and defense buyers? Our sponsored listings and data-verified articles on The Armor List are a great place to start. Boost visibility, credibility, and verified compliance — all in one listing.
Visit armorlist.com/advertising or contact support@intelalytic.com today.
