New U.S. Body Armor to Protect Soldiers' Limbs

ABERDEEN PROVING GROUND, Md., July 4, 2005 — -- Until now, body armor for troops in Iraq has provided protection for much of the body -- but not for arms and legs.

Among the thousands of U.S. wounded, an unprecedented 6 percent have had amputations. That's double the rate in previous wars.

But there is new hope -- new armor worn over the combat uniform to protect limbs and other body parts. The protection is provided by several layers of polyethylene fiber.

"The new body armor is excellent," Army Pvt. Ronald Smith said. "Mobility, light, protection -- I'll wear it."

Each layer of the fiber individually doesn't look like much: It's flexible and very thin and looks a bit like plastic sheeting.

But scientists say it is 15 times stronger than steel. And when hit by a bullet, it bends but doesn't break.

The military believes the armor could provide major protection for convoys, prime targets for roadside attacks.

Eventually, each set will be tailored to the size of the service member. But right now, it's one size fits all, and it weighs 10 pounds.

That's a problem for a small woman like Marine Sgt. Shaelynn York.

"My legs could only go so far," she said. "So, that was the problem that I ran into. Other than that, it was OK."

No one likes the extra weight. But those who have tried it say that's a small price to pay.

"I'll definitely put on 20 more pounds if it means I'm going to save a limb, come back to my family as a whole person," Army Staff Sgt. Anthony Manke said.

The military is rushing production to send 4,500 sets of the armor to Iraq this summer and thousands more by the end of the year. Each set will cost $1,500.

ABC News' John Cochran originally reported this story for "World News Tonight" on June 26, 2005.