What Do Bulletproof Cars And Military Vehicles Have In Common?

A diplomat’s limousine and a military MRAP have more in common than meets the eye. At first glance, they are dramatically different. One has a sleek design, crafted as a statement of sophistication; the other is a bulky vehicle that can hover through landmines. However, under their surfaces, similar technologies operate to keep drivers and passengers safe.

Indeed, bulletproof luxury cars and tactical military vehicles share the same ethos: both have been designed for survivability. Due to geopolitical tensions and increased gun violence in urban areas, politicians, diplomats, and CEOs have been investing in modernized defense systems for their vehicles. Unsurprisingly, this industry is set to grow at a 5.4% CAGR until 2030, registering a global market size of USD 32.41 billion in 2024. 

What do bulletproof cars and military vehicles have in common? Keep reading and find out. 

Ballistic Armor Technology

Arguably, the most relevant similarity between the two vehicles is their ballistic resistance. Ballistic resistance goes beyond bulletproof glass on windows; the whole chassis must be strengthened. In both cases, manufacturers use ballistic steel alloys and composite materials that are highly impact-resistant and applied to the vehicle’s internal and external parts.

The internal protective layer, called the spall liner, is present on both luxury and military vehicles. The name derives from “spall,” a fragment of metal coming from the impact of bullets or explosions on the outer hull. Typically, spall liners are made from aramid, fiberglass, and other high-strength materials. 

More importantly, such materials must be lightweight to improve fuel efficiency and maneuverability, whether in urban areas, gritty off-road tracks, or war zones. For instance, tactical vehicles like Plasan’s sandcat are built based on the Ford F-550 chassis, a sturdy pickup truck that naturally balances such features. 

Armored Windshields and Windows

When it comes to windshields and windows, absorbing bullet impact isn’t enough. Without appropriate treatment, such an impact can release deadly shrapnel inside the vehicle. For this reason, manufacturers combine multiple layers of glass with strong polymers (such as vinyl or polycarbonate), then heat them at high temperatures while applying mechanical pressure to bond them together.

So, when a bullet hits the glass, it not only keeps it outside but also prevents glass shrapnel from being released inside the vehicle. Modern armored glasses use LTA (Lightweight Transparent Armor), capable of resisting even armor-piercing rounds. The same multi-shield principle is applied to civilian and military vehicles alike. 

Special Run-Flat Tires

The best armor would be pointless if mounted over regular tires. It can be easily damaged by bullet punctures, impairing mobility when it’s most needed. After all, having to come out of the vehicle to replace a punctured tire while rounds are being fired would defeat an armored vehicle’s primary purpose: self-defense.  

Run-flat tires remain functional even after an attack, allowing drivers and passengers to steer away from danger. After being punctured, these tires can still be driven long distances without losing stability or maneuverability, thanks to their reinforced sidewalls. It’s not an exaggeration to say that soldiers in war zones, CEOs,  and heads of state need a similar level of protection these days.

Similar Stories