Reference Pieces (the clothing items we’re pointing at)
Cards mirror your reference layout
Click to zoom
Reference Piece
Baseline Vest (What’s wrong with typical soft armor carriers)
Use this as the baseline example: typical soft-armor carriers often trade comfort and concealment for bulk, and performance depends heavily on rating, fit, and shot placement. This dossier contrasts that baseline with a system-focused approach (coverage continuity + trauma management).
carrier fitcoverage zonesconcealment
Click to zoom
Reference Piece
Outer Jacket (Tailored shell)
The outward-facing piece: hides panels, controls printing, and provides structure.
concealmentstructureouter shell
Click to zoom
Reference Piece
Inner Vest / Carrier (Primary stop)
The core soft-armor package sits here; this is the main stopping layer in their system.
primary stopsoft armormulti-hit spacing
Click to zoom
Reference Piece
Layer Proof (Sample panel hit)
A small test square showing the vest layup after impact (visual evidence of the stack concept).
test panelimpactstack
Click to zoom
Reference Piece
Reference Collage (Concept vibe)
A collage-style reference frame for layout, storytelling, and piece-by-piece breakdown.
layout referencestorytellingpieces
Baseline Vest Limitations (Why “regular” vests feel disappointing)
High-level performance framing (NIJ concepts, not instructions)
What typically goes wrong
- Coverage gaps: armholes, side seams, and waistline “gap lines” are common weak points in everyday wear.
- Blunt trauma: stopping penetration can still transmit a serious impulse (backface deformation / bruising / rib injury risk).
- Fit drift: movement (sitting, twisting) shifts panels; protection is only as good as alignment over time.
- Multi-hit reality: soft armor can handle multiple impacts, but performance depends on spacing, local damage, and deformation.
Typical soft-armor carriers are optimized for specific ballistic threats; everyday risks can also include slashing/puncture hazards. A thin, system-wide stab-resistant outer liner concept can help protect the garment surfaces and reduce cut/puncture vulnerability without changing the underlying ballistic stack.
“Math” without hype
Ballistic performance isn’t additive like “one more layer = X% more bulletproof.” Real outcomes depend on the NIJ threat level,
projectile type, velocity, angle, shot spacing, and how the system manages energy + deformation.
The most meaningful improvement you can make in a wearable system is usually:
- maintain consistent coverage continuity (reduce gap lines), and
- add a trauma / energy management layer so “stopped” doesn’t still mean “crippling hit”.
Hacksmith Disclosed Material Layers (what’s actually stated/shown)
Keep this section factual-only
What they used (families)
- Published material families: aramid (Kevlar-class) + UHMWPE (Dyneema-class) used as a tested composite stack.
- Jacket package: disclosed as a 16-layer composite (~3.4 mm) designed to remain flexible enough for tailoring.
- Vest package: shown/claimed as a higher-layer-count soft-armor carrier (often cited around ~20 layers in their promo/video framing).
Important: the exact ply-by-ply order (e.g., “layer 1 = X, layer 2 = Y…”) is not fully published by them; this page sticks to what they show/state at a materials-family + layer-count level.
Pieces (where the stack lives)
- Jacket: tailored shell + integrated composite panels (their “16-layer” composite package).
- Vest/carrier: primary soft-armor package worn under the jacket; provides the main stopping performance.
- Inner shirt: comfort layer only (fit, moisture, chafe control).
Goal of this page: present the pieces clearly and then add a body-side improvement layer concept that addresses blunt trauma + comfort without changing the aesthetic.
Body “Gap-Closer” Upgrade (conceptual layer behind the ballistic stack)
Targets trauma + heat + multi-hit consistency
What closes the gap (body-side)
- Trauma / energy management: a body-facing subsystem that reduces backface deformation and spreads impulse (spacer mesh, rate-sensitive padding, STF-type behavior).
- Hybrid + orientation diversity: UHMWPE + aramid roles complement each other; diverse orientations improve multi-hit consistency and fold tolerance.
- Anti-spall + comfort liner: fragment capture + heat/chafe management so the system is wearable and stays aligned.
Why this matters
Stopping the projectile isn’t the whole problem: the “remaining discrepancies” are mostly blunt trauma, fit drift, heat, and multi-hit robustness.
The gap-closer adds energy management and wearability without changing the outward look.
Pants Concept Variants (since Hacksmith didn’t do the pants)
Concept-only: fit, comfort, and coverage goals (not a build guide)
Variant A — Heavy “Protection-First” Trouser
- Outer liner: add a stab-resistant outer liner concept to improve cut/puncture resilience for the garment surface.
- Goal: maximize coverage in high-risk zones while keeping motion workable (walking, sitting, stairs).
- Coverage priority: upper legs/hips + waistband overlap with the vest/jacket stack to reduce “gap lines”.
- Comfort priority: internal comfort liner + ventilation channels to prevent heat soak and chafing.
- System principle: treat lower-body protection as a separate subsystem whose job is to reduce injury risk and improve overall wear consistency.
Note: This page intentionally avoids step-by-step instructions, specific layer counts, or construction details.
Variant B — Light “Concealment-First” Trouser
- Outer liner: add a stab-resistant outer liner concept to improve everyday cut/puncture resilience while preserving drape.
- Goal: preserve normal suit drape and comfort while adding a modest risk-reduction layer.
- Coverage priority: high-mobility areas where bulk is most noticeable (front thigh, outer hip).
- Wearability: minimal heat penalty, minimal stiffness, minimal printing under tailored fabric.
- Use case: “looks and feels normal” while improving baseline protection compared to standard clothing.
Final System View (outer → inner)
High-level stack map (no build steps)
Stack Map
Tailored Suit Jacket (outer shell)
↓
Stab-resistant outer liner (concept: cut/puncture resistance at garment surface)
↓
Hacksmith jacket composite package (aramid + UHMWPE family; 16-layer composite stated)
↓
Primary vest/carrier package (soft armor stack; aramid + UHMWPE family; higher layer-count referenced in promo/video framing)
↓
Body-side “gap-closer” (trauma / energy management + anti-spall + comfort liner concepts)
↓
Body
DIY Segment (Process Streamlining & Cost Framing)
Concept-only: workflow visualization, not instructions
Why include a DIY segment
- Transparency: shows how prototyping and iteration could be streamlined without revealing build steps.
- Cost framing: communicates that material waste, iteration cycles, and logistics dominate real costs—not just raw fabrics.
- Repeatability: visualizes controlled, repeatable processing for test coupons, liners, carriers, and non-ballistic components.
- Outer liner concept: the stab-resistant liner is treated as a garment-facing durability layer; prototyping focuses on fit, comfort, and wear resistance (not ballistic performance).
Boundary: This section is intentionally non-operational. It illustrates workflow and budgeting considerations only.
Workflow visualization (example tool)
A compact desktop cutter/engraver (shown here) represents how teams often streamline non-ballistic parts of a project: carriers, spacers, liners, templates, jigs, labels, and documentation assets.
The takeaway is not the tool itself, but the process discipline: rapid iteration, consistent geometry, and predictable material usage.
Click to zoom
DIY / PROCESS
Workflow & Cost Streamlining Visual
Used here as a visual stand-in for disciplined prototyping workflows that reduce
iteration cost and improve consistency for support components (liners,
spacers, carriers, templates)—not ballistic elements.
process
iteration
cost framing
non-ballistic