Ballistic Armor Comfort & Mobility Testing

PPE must be comfortable.

Maximizing the comfort and mobility of body armor (such as ballistic gear and bulletproof vests) is key for law enforcement and military forces.

To support the user experience, we worked with DuPont to develop three test methods. The assessment addresses the comfort issues specific to soft ballistic inserts.

Inspired by real-world user situations and body movements, these tests identify discomfort levels and mobility constraints that wearers may experience during their respective operations.

Tests for Ballistic Armor Comfort Assessment

DuPont x Hohenstein Collaboration

Mobility - Lower Costal Bending
Mobility - Double Curvature Compression
Comfort - Edge Pressure

Mobility - Lower Costal Bending

Scans with red pain points highlighted in two scenarios with wearer in bent position — Scans highlight pain points for wearers in bending positions. ©DuPont 2024

Scan of woman wearing ballistic vest in a bent position with test apparatus at the same angles — The LCB test is designed to match the PPE wearer's natural bending movements. ©DuPont 2024

Ballistic vest bent over Hohenstein test equipment with 2220 Nmm measurement — The LCB test quantifies energy lost during a bending movement due to the stiffness of the ballistic vest. ©DuPont 2024

Mobility Assessment Using Lower Costal Bending (LCB) Test

Test Method Reference: HO-DPT 67474-2

Multiple bending movements lead to energy loss and accelerated exhaustion for the wearer.

The Lower Costal Bending (LCB) test replicates the bending movement of an upper body to quantify lost energy from stiff ballistic gear.

Mobility - Double Curvature Compression

Scans with red pain points highlighted in two scenarios with wearer in squatting positions — Scans highlight pain points for wearers in squatting positions. ©DuPont 2024

Scan of man wearing a ballistic vest with highlighted bends in surface of torso — The DCC test is designed to match the curves in the PPE wearer's torso. ©DuPont 2024

Ballistic material in curved Hohenstein test equipment with 2362 Nmm measurement — The DCC test quantifies the energy needed for ballistic gear to conform to a double curvature shape during a bending movement. ©DuPont 2024

Mobility Assessment Using Double Curvature Compression (DCC) Test

Test Method Reference: HO-DPT 67474-3

For freedom of movement and optimized mobility, ballistic gear needs to conform to the wearer’s body. Our testing considers the users in motion and in real-life situations.

Using digital imaging, we study how body armor conforms to shapes with multiple curves. A high degree of adaptability enables more movement for the user.

The Double Curvature Compression (DCC) test replicates the shape of a bent torso to measure the adaptability of ballistic materials. Then, we quantify the energy needed for ballistic gear to adapt.

Comfort - Edge Pressure

Scans with red pain points highlighted in two scenarios with wearer having outstretched arms — Scans highlight pain points at the edges of ballistic vests. ©DuPont 2024

Scan of ballistic vest next to matching test apparatus — The Edge Pressure (EP) test is designed to match the PPE wearer's natural movements and detect pain points at the edges of the gear. ©DuPont 2024

Ballistic material in Hohenstein test equipment with 63 N measurement at the edge — The EP test quantifies the discomfort caused by ballistic gear at localized pressure points. ©DuPont 2024

Comfort Assessment Using Edge Pressure (EP) Test

Test Method Reference: HO-DPT 67474-1

The edges of a ballistic vest can cause discomfort at pressure points (e.g. lower abdomen, neck, arms).

The Edge Pressure (EP) test replicates the shape of an arm and the curvature of the ballistic gear to quantify discomfort generated at localized pressure points.