How bulletproof glass is made: materials, layers and testing
Bulletproof glass is manufactured differently from standard laminated glass. Learn how it's made and how it's tested.

Remember shatterproof rulers? These staples of school pencil cases had a dark secret: they weren't actually shatterproof.
"Shatterproof", you see, means indestructible – and shatterproof rulers can be shattered if you try hard enough and apply enough force.
The same goes for bulletproof glass, also known as "ballistic-proof glass". Bulletproof glass can stop a bullet from penetrating a glass unit and getting to the other side – but that doesn't mean its glass layers remain intact.
The level of ballistic resistance depends on the protection level of the glass and the frame. This level is determined by the risk that a bullet would present to property and human life.
To take an easy example: who needs a higher level of bullet resistance – the local post office or a military facility? This is partly because of the threat level and partly because of the kinds of firearms that might be used in those two locations.
Here at Wrightstyle, our advanced ballistic systems include both the glass and its frame and offer protection from a range of firearms. In this guide, we explore how ballistic-proof glass is made and how it's tested.
How is bulletproof glass made?
Bulletproof glass – also known as "ballistic-proof glass" and "bullet-resistant glass" – is made by laminating multiple layers of glass with tough and transparent plastic interlayers. These are often made from polyvinyl butyral (PVB).
As well as the PVB interlayer, bulletproof glass typically includes thicker polycarbonate or acrylic layers. These help absorb the energy of the bullet and stop the unit from shattering.
How does bulletproof glass work?
When a bullet is fired at a sheet of ballistic glass, it will penetrate the glass layers. However, the polycarbonate or acrylic substrate sandwiched between the outer sheets of glass absorbs the bullet's kinetic energy and stops it from penetrating the final layer.
For bulletproof glass manufacturers, the key is to balance strength and flexibility. The laminate must be tough, for obvious reasons. But it must also flex enough that it gives the kinetic energy somewhere to go. If the plastic layer were too stiff, it would also crack when hit by a bullet.
Protection against different firearms and projectiles
Bulletproof glass is manufactured to protect against different kinds of ballistic projectiles – from shotguns all the way through to 9mm and .44 magnum handguns.
A petrol station or bank, say, might want to protect against shotguns and handguns. But in other settings, protection is required against rifles with armour-piercing capabilities.
The velocity of the bullet and the type of the bullet affect how far it can penetrate into building components. Bullet velocity is measured in meters per second (m/s). These are the most typical bullet velocities:
- Handguns: 300 to 500 m/s
- Rifles: 700 to 1,000 m/s
- Shotguns: about 600 m/s
Before ballistic-proof glass goes to market, it must be comprehensively tested. The life-saving nature of the product means testing is essential rather than optional.
How is ballistic-proof glass tested?
Here at Wrightstyle, all our glazing systems and specialist glass products are tested in real-world simulations. This means that actual bullets are fired at actual glass.
We undertake ballistic testing in a UKAS-accredited test laboratory. Here, products are tested to the British and European standards DIN EN 1522 (framing) and DIN EN 1063 (glass).
These are the most stringent tests. Products that meet these standards are trusted to provide the highest levels of protection against firearms of all kinds.
A glazing system is more than just glass, however. The whole glazing system has to be bulletproof.
For this reason, we test our range of ballistic steel glazing systems to the following international standards:
- CEN 1063 BR1 to BR7
- BS5051 G1 to R2ap
- STANAG 4569 levels 1 to 3
- DIN 52290 levels 1 to 5
- UL752-1991
- UNE 108-131086 levels 1 to 5
All our manufacturing processes are undertaken to Quality Management System BS EN ISO 9001: 2015. This ensures our manufacturing processes are consistent by way of regular audits.
You can see examples of our live ballistic testing over on our YouTube channel. Here's an example.
What is a ballistic-proof glazing system?
A common misconception is that only the glass in a glazing system needs to be rated. However, the frame also needs to match the specified threat level to ensure a complete engineered solution that protects building users. Together, they comprise a ballistic-proof glazing system.
Our advanced ballistic systems include both specialist glass and a specialist frame. It's designed to serve as a primary system against ballistic attack and to offer protection from a wide range of firearms.
Like all ballistic-proof glazing systems, it's a specialised and multi-layered assembly of bulletproof glass, flexible plastics, interlayers and rated frames.
What we offer
At Wrightstyle, we offer a range of bullet-resistant glazing systems with or without glass and installation.
These include:
- Large-span curtain wall systems (the SR series)
- Blast-resistant curtain walls (the SG series)
- Bulletproof windows, doors and screens in our 60 series – so-called because of its narrow 60mm sightlines
On top of this, we can offer ballistic
and fire-rated systems. These include:
- The 60F1 series of fire-rated and bulletproof windows, doors and screens
- Our
fire-rated curtain walls, offering up to 120-minute integrity and insulation fire protection
But we don't just supply glazing systems to our clients. We also provide expert guidance, from specification and estimating to design and structural calculations.
And while our work is highly specialised, we pride ourselves on being able to communicate clearly with all our clients.
Do you need help finding the right product for the job? Please don't hesitate to
get in touch with our UK experts for step-by-step technical support and product advice.
Ballistic glass FAQs
Can bulletproof glass be fire-rated?
Yes, bulletproof glass can be fire-rated and bulletproof glazing systems can be fire-rated, too. The same goes for blast-resistant curtain walls, doors, windows and screens.
If the glass cracks, is it still bulletproof?
Glass can never be truly "bulletproof" – but it can be bullet-resistant. The glass layers can crack, but the unit as a whole stops the bullet from reaching the other side.
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