Helicopter Armor by Safe Pro USA

Ballistic Protection Systems for
Military Rotary Wing Aircraft

30+ Years Defense Expertise • Made in the USA • NIJ & DoD Tested • Airworthiness Certified • Rapid Response Team

Helicopter Armor

Capabilities

Safe Pro USA brings more than 30 years of defense armor expertise to the rapid design, development, manufacturing, and installation of the lightest ballistic protection systems for military rotary wing aircraft. Using advanced UHMWPE unidirectional fiber and Boron Carbide composites, we achieve the lowest weight per square foot while defeating specified threat levels.

Our complete engineering approach covers ballistic and geometry optimization, crashworthy attachment systems that require no airframe modifications, human-factors design, logistics, independent NIJ testing, and on-site training — delivering mission-ready, airworthiness-supported solutions for the CH-47 Chinook, CH-53E Super Stallion, UH-60 Black Hawk family, and other critical platforms.

Featured Aircraft

Boeing CH-47 Chinook

Heavy-lift workhorse. Custom lightweight BPS armor systems engineered for crew protection, cargo areas, and ramp configurations while preserving maximum payload capacity.

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Sikorsky CH-53E Super Stallion

Including specialized ramp armor solutions. Extremely lightweight panels designed for the largest U.S. military helicopter with full crashworthy attachment and rapid B-Kit install/removal.

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Lockheed Martin / Sikorsky UH-60 Black Hawk

Industry benchmark for utility and special operations. Our systems achieve <20-minute installation by two personnel with quick-disconnect fasteners and no tools required for B-Kit removal.

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Reasons for Choosing Safe Pro USA
Aircraft Armor by Defense & Military Teams

  • True End-to-End Rapid Response Capability

    Complete in-house control of design, ballistic & structural engineering, modular manufacturing, and on-site installation training (CONUS & OCONUS).

  • Extremely Lightweight Starting from 2 PSF

    Advanced UHMWPE unidirectional fiber and Boron Carbide/Silicone composites deliver some of the lowest weight per square foot while defeating the specified threat spectrum, maximizing payload, range, and maneuverability.

  • 30+ Years of Helicopter Armor Expertise

    Decades of experience in ballistic design, human factors engineering, crashworthy structures, and mission-ready logistics from concept through airworthiness certification.

  • Full Support for Transport & Utility Helicopters

    Proven systems for the CH-47/MH-47 Chinook, CH-53E Super Stallion, UH-60/MH-60 Black Hawk family, and many more rotary-wing platforms. Rapid custom engineering available for additional aircraft.

Safe Pro USA Team Expertise

Backed by deep collaboration with the Technology Applications Program Office (TAPO) and RDEC, the Safe Pro USA team possesses unparalleled expertise in next-generation armor design and complete airworthiness certification — ensuring our protective systems exceed the rigorous requirements of military, law enforcement, and tactical professionals.

Full Manufacturer Compatibility

Safe Pro USA Logo | Body Armor, Plate Carriers & Tactical Gear

Engineered with the Most Advanced Lightweight Composites

Safe Pro USA Helicopter Armor Systems

Safe Pro USA aircraft BPS armor utilizes premium Ultra-High-Molecular-Weight Polyethylene (UHMWPE) unidirectional fiber. Advanced armor systems are constructed with Boron Carbide and Silicone Carbide ceramic composites.

This hybrid construction achieves superior multi-hit performance at a fraction of the weight of traditional steel or older composite systems — directly translating to increased range, payload, and survivability for aircrews and passengers.

FAQ

Still have questions about integrating lightweight ballistic protection into your rotary wing fleet? Below are clear, direct answers to the most common questions we receive from aviation program managers, safety officers, and defense acquisition teams.
What threat levels do Safe Pro USA aircraft BPS systems protect against?

Systems are engineered to defeat the full specified threat spectrum for rotary-wing aircraft, including small arms fire and fragmentation, while maintaining the lowest possible weight.
Do you need to modify the aircraft airframe to install the armor?

No. All systems are designed to attach to existing hard points using custom-engineered brackets. No structural modifications to the airframe are required.
How lightweight are your systems compared to traditional armor?

Safe Pro USA’s UHMWPE and Boron Carbide/Silicone Carbide composite armor solutions, deliver among the lowest weight per square foot in the industry for the required protection level, significantly enabling greater mission payloads.
What is the typical timeline from initial inquiry to delivery?

Our rapid-response team excels at performing at compressed timelines. Modular CAD/CAM design, manufacturing and in-house capabilities allow for fast design, testing, at scale manufacturing, and CONUS/OCONUS installation training to the end users.

ARMOR UP

Ready to Armor Your Fleet?

Protect your Helicopter Fleet with Ultra Lightweight and Advanced Aircraft Armor. Partner with the team that combines 30+ years of defense armor expertise with true rapid-response capability from design, development, prototyping, testing, manufacturing and installation.
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