Bullet-proof custard: British soldiers could be wearing revolutionary new liquid body armour within two years



A revolutionary new form of body armour nicknamed 'bullet-proof custard' has been invented to help save British troops' lives.

Scientists have created a top-secret substance that absorbs the force of a shot or shrapnel by thickening and hardening instantly on impact.

Defence chiefs believe bulletproof jackets made from the goo will be lighter, more flexible and offer greater protection for soldiers on the battlefield.

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Test: High-speed video shows a bullet hitting ten layers of Kevlar treated with liquid armour 'custard' (top photos). The bottom row shows a bullet fired at 31 layers of untreated Kevlar



The hi-tech 'liquid armour' was showcased at a defence conference in London today at which companies displayed an array of James Bond-style gadgets and gizmos.

Researchers have inserted the futuristic formula - called a 'shear thickening fluid' - between sheets of traditional Kevlar to produce the 'super armour'.

The liquid has been compared to custard because the molecules lock together and 'thicken' in the same way as the dessert sauce reacts to being stirred when heated.

Experts say this will create armour that is about half as heavy as standard bullet-proof vests which allows greater manoeuvrability for troops.

Soldiers currently struggle with bulky body armour made up of ceramic plates and layered Kevlar, which is five times stronger than steel but can restrict movement.

It is also uncomfortable in hot war zones like Afghanistan, where temperatures soar in the summer to 50C.

Four-wheel drive: A defence conference in London today saw an array of James Bond-style gadgets including this all-terrain terrestrial remote-controlled vehicle fitted with a camera unit Keeping in touch: A portable keypad system that soldiers can strap to their armour and take with them into combat

The pioneering technology has been created by a team of scientists at the global defence and security company BAE systems in Filton, Bristol.

Researchers tested the material by firing bullets from a 9mm handgun into 31 layers of untreated Kevlar and 10 layers of Kevlar combined with the 'custard'.

When the liquid armour was struck by the projectile, the impact was dispersed over a wider area.

This reduces the chances of soldiers being injured or killed by the force of a bullet because it is not concentrated on one small area.

Troops who have survived being shot in their armour have suffered deep bruising, cracked ribs and even damaged internal organs.

BAe Systems will develop the liquid armour so it can take the force of more powerful guns, including the AK47 assault rifle used by the Taliban.

The company believes soldiers could be using the new protective vests in two years.

Nick Haigh, a spokesman for BAe Systems, said: 'There is a fair amount of interest from the Ministry of Defence and we hop that it ends up being worn by frontline troops.

'Traditional Kevlar protective vests is very effective but it is massively heavy and bulky. If we are able to reduce the weight burden for soldiers they will be able to do their jobs more effectively.'

FUTURE OF THE ARMY UNIFORM?



One device showcased was an army uniform that conducts electricity and computer data through internally woven 'conductive yarns'.

Devised by Intelligent Textiles, a Staines-based technology company, it allows troops to attach electrical equipment such as handheld computers, radios and mobile phones to powerpoints on their uniform. Because the uniform runs off a central battery pack attached to the fabric, it helps lighten the load carried by soldiers because they do not need cables and batteries. PORTABLE OXYGEN GENERATOR



Another organisation is developing a portable oxygen generator to save lives on the frontline - using an engine dating back to before the Boer War.



Soldiers on patrol do not carry pressurised canisters because they are too heavy and it is a safety risk.



However, a serviceman receiving oxygen within an hour of being wounded - the so-called 'golden hour' - sees their chances of survival increase dramatically.

In addition to increasing the ballistic performance of combat body armour there is potential for developing a version that could be used by police forces and ambulance crews.

Defence equipment minister Peter Luff, who attended the event, said: 'While future weapons and ingenious gadgets are the stock-in-trade of any James Bond film, and are all very exciting, we must ensure that ingenuity translates into combat edge in the field.

'That's exactly what I have just seen and I am extremely impressed by it.'

With ceramic plates, a soldier's flak jacket weighs 10kg. BAe Systems hopes that the liquid armour could weigh half as much.

The innovations are funded through the Centre for Defence Enterprise, an initiative that aims to harness British scientific developments for rapid use on the battlefield.