Improving Military Gear Design through Comprehensive Usability Evaluation: A Case Study on ROK Army Combat Vests

Objective: This study aims to identify ergonomic challenges in Republic of Korea (ROK) Army combat vests through a comprehensive usability evaluation and propose targeted design improvements.<br/><br/>Background: To enhance combat effectiveness and survivability amid declining troop numbers, the ROK Army has promoted the Warrior Platform initiative to modernize individual combat systems. Combat vests with Modular Lightweight Load-carrying Equipment (MOLLE) have been deployed, but issues remain regarding load burden, mobility restriction, and poor ergonomic fit. Prior evaluations have relied heavily on subjective evaluation and lacked scientific criteria. A structured, data-driven evaluation approach is therefore essential to validate usability and inform design optimization.<br/><br/>Method: Three combat vest designs (Designs A – C) were evaluated with four active-duty ROK Army soldiers. The study incorporated a multifaceted evaluation protocol, including design and size analysis, clothing pressure measurement, joint range of motion (ROM) analysis, and a subjective usability survey. Clothing pressure was measured using pneumatic sensors, and joint ROMs were assessed with an IMU-based motion capture system.<br/><br/>Results: The evaluation revealed noticeable differences in neckline configuration, armhole depth, strap placement, waist belt structure, and MOLLE capacity. Design A exhibited the highest pressure at the shoulders and back. Design B demonstrated effective load distribution but restricted lumbar mobility to a degree, due to an added support strap. Design C allowed better mobility but lacked adequate stability. Subjective evaluation aligned with the quantitative findings with participants favoring Design B. Based on the results, improvements were suggested, including refining armhole curves, extending the hemline, and repositioning straps.<br/><br/>Conclusion: The findings highlight how specific design elements impact wearability and mobility, offering evidence-based guidance for selecting and enhancing ROK Army combat vest designs.<br/><br/>Application: The evaluation protocol established in this study can be applied to other military and performance gears to identify design opportunities and guide future development strategies.