Optimization of bulletproof vest design for the police: controlled simulations in a user-centered approach to assess the suitability of a MOLLE bulletproof vest for the comfort and effectiveness of patrol officers.

We conducted simulations to assess the design of a bulletproof vest integrating a Modular Lightweight Load-carrying Equipment (MOLLE) system and its compatibility with police patrol activities. By combining design and ergonomics, our study highlights key improvements in mobility, comfort, and equipment organization. Fifteen officers with diverse body types tested these vests in a controlled environment, performing tasks such as entering and exiting vehicles, competing a report, as well as handling various pieces of equipment. The results indicate positive feedback regarding safety, the modularity of the MOLLE system, and the vest’s aesthetics. However, several shortcomings were identified: improper equipment positioning hindering accessibility and comfort, rigid ballistic panel edges restricting mobility, and the attachment system and excessive bulk at the front of the vest complicate tool handling and increase physical strain. Our findings emphasize the need to redistribute equipment weight, optimize tool placement, and adapt the load to officers’ body sizes. By incorporating feedback from patrol officers and collaborating with manufacturers, we aim to refine the vest’s design to enhance both performance and user well-being.