Polyethylene solutions are extruded through a multi-orifice spinneret into a cross-flow gas
stream to form a fluid product. The fluid product is stretched at a temperature at which a gel will form at a
stretch ratio of at least 5:1 over a length of less than about 25 mm with the cross-flow gas
stream velocity at less than about 3m / min. The fluid product is quenched in a quench bath consisting of an immiscible liquid to form a gel. The gel is stretched. The
solvent is removed from the gel to form a xerogel and the xerogel product is stretched in at least two stages to produce a
polyethylene yarn characterized by a tenacity of at least 35g / d, a modulus of at least 1600 g / d and a work to break of at least 65 J / g. The
yarn is further characterized by having greater than about 60 % of a
high strain orthorhombic crystalline component and, optionally, a monoclinic crystalline component greater than about 2 % of the crystalline content. Composite panels made with these yarns exhibit excellent
ballistic resistance, e.g., SEAC of 300J-m<2> / Kg or higher against .38
caliber bullets using test procedure NILECJ-STD-0101.01. A ballistic resistant composite panel is provided comprising a
polyethylene multi-
filament yarn having a tenacity of at least about 35 g / d, a modulus of at least 1600 g / d, a work-to-break of at least about 65 J / g wherein the
yarn has greater than about 60 % of a
high strain orthorhombic crystalline component and the yarn has a monoclinic crystalline component greater than about 2 % of the crystalline content.