Reengineering Body-Worn Protection Systems for Performance and Fit
My Role
As the Lead Industrial Designer for the Version 2 redesign of the Angel Armor carrier system, I led the redevelopment of the product line through user-centered research, apparel engineering, and manufacturing optimization. My work focused on improving fit, ergonomics, adjustability, hidden storage, hardware integration, moisture management, pattern development, grading, prototyping, and production readiness while creating scalable solutions for custom sizing and manufacturing efficiency.
Beyond product development, I established design and engineering workflows by training the incoming industrial design, engineering, product development, and prototyping teams on Optitex pattern development, SolidWorks file management, production documentation, prototype assembly, and manufacturing processes to ensure long-term continuity across the organization.
Research & Design Process
The redesign was informed by field research with law enforcement professionals, including empathy studies, user testing across diverse body types, and surveys evaluating equipment storage needs. These insights guided improvements to carrier fit, donning and doffing, shoulder adjustment systems, hidden storage, hardware integration, moisture-wicking materials, and manufacturable pattern construction.
Collaborators
The original Angel Armor carrier platform was designed by Ryan Miller (Industrial Design, 2017–2021) in collaboration with Derrick King (Engineering, 2015–2021). I joined the program in 2021 to lead the Version 2 redesign, manufacturing improvements, and organizational knowledge transfer. The concept ideation sketches and illustrations featured in this case study were created by Ryan Miller and are included to provide design context for the evolution of the product.
Let's Continue the Conversation
Many of my projects were developed under confidential client agreements, so only a portion of the work can be shared publicly. If you're interested in seeing additional research, design iterations, prototypes, engineering documentation, or production development for this project, I'd be happy to share more during a private portfolio review.
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