In this study, various types of advanced-grade Polyester fabrics in digital camouflage and disruptive print were explored to find the most suitable one as the outer shell fabric (OSF) for bulletproof jacket (BPJ). These fabrics were developed in two different weave designs (rip stop and plain) with varying the areal densities (200 g/m2, 232 g/m2 and 253 g/m2) and were also coated with thermoplastic-grade polyurethane (TPU). The results of the study showed that the Polyester fabric with an areal density of 232 g/m2 was among the most suitable material for the OSF, based on the mechanical properties. However the other functional features are comparable with the two other fabrics (200 g/m2 and 253 g/m2). This fabric displayed improved durability in terms of superior mechanical properties; breaking, tear and bursting strength and excellent abrasion resistance (insignificant weight loss and no fibre damage) compared to the existing version OSF of IS: 17,051 and GSQR 1438. The colour characterization (x, y and z and ΔE) of the print pattern of the selected Polyester OSF is carried out for the assessment of extent of variation from the digital camouflage pattern.