Abstract
Personal armors were initially designed to fit against the male torso, as men previously filled roles requiring them, thus not made to accommodate the female anatomy. As a result, armor worn by female warfighters tends to have non-form fit in the waist, armpit, bust, and collarbone areas, causing reduced coverage. Shifting, riding up, air gaps, breathing difficulty, and physical discomfort have also been observed. Although this has been documented, the impact on the armor’s protective capabilities has not been well studied. To address this, this study compared the protective capabilities of unisex armor for male and female warfighters from shock threats. Instrumented manikins were exposed to free-field blasts to assess pressure exposure in as-worn conditions. Directionality effects were considered in this study, using five directions from the shock source. It was found that the most harmful exposure to both warfighters occurred during a head-on interaction, with average impulse values 9.7%-72.6% higher than other orientations and peak pressures being 111.0 and 107.9 kPa, respectively. Moreover, a female body shape altered armor fit to increase impulses by up to 78.6%, relative to no armor being worn. This result was not observed for the male warfighter, though peak pressures were reduced for both.
Similar content being viewed by others
Data availability
The datasets generated during and/or analyzed during the current study are available from the corresponding author on reasonable request.
References
Bhatia, D., Jaswal, P. & Sinha, S. Women’s body armor: A comprehensive review of design, performance, and ergonomics. J. Eng. Fibers Fabr. 19, 15589250241232151 (2024).
Coltman, C. E., Steele, J. R., Spratford, W. A. & Molloy, R. H. Are female soldiers satisfied with the fit and function of body armour? Appl. Ergon. 89, 103197 (2020).
Coltman, C. E., Brisbine, B. R., Molloy, R. H. & Steele, J. R. Effect of Torso and Breast Characteristics on the Perceived Fit of Body Armour Systems Among Female Soldiers: Implications for Body Armour Sizing and Design. Front. Sports Act. Living. 4, 821210 (2022).
Armstrong, N. C. et al. Clothing and individual equipment for the female soldier: developing a framework to improve the evidence base which informs future design and evaluation. BMJ Mil Health. https://doi.org/10.1136/military-2024-002735 (2024).
Prochner, I. Designing for Sex and Gender Equity (Routledge, 2023). https://doi.org/10.4324/9781003306320
Kordani, N. Advances in Healthcare and Protective Textiles: Body Armor (Woodhead Publishing, 2023).
Tilsley, L., Carr, D. J., Lankester, C. & Malbon, C. Do air-gaps behind soft body armour affect protection? J. R Army Med. Corps. 164, 15–18 (2018).
Sarvghad-Moghaddam, H., Rezaei, A., Ziejewski, M. & Karami, G. Evaluation of brain tissue responses because of the underwash overpressure of helmet and faceshield under blast loading. Numer. Methods Biomed. Eng. 33, e02782 (2017).
Chanda, A. & Graeter, R. Human Skin-Like Composite Materials for Blast Induced Injury Mitigation. J. Compos. Sci. 2, 44 (2018).
Li, J. et al. Protective Mechanism of Helmet Under Far-field Shock Wave. Int. J. Impact Eng. 143, 103617 (2020).
Cooper, P. W. Explosives Engineering (Wiley-VCH, 2018).
Thomas, C. J. H. & Johnson, C. E. Investigation into helmet–head shock wave interactions at low overpressures through free-field blasts and schlieren imagery | Shock Waves. Shock Waves. https://doi.org/10.1007/s00193-024-01167-4 (2024).
Sekine, Y. et al. Efficacy of Body Armor in Protection Against Blast Injuries Using a Swine Model in a Confined Space with a Blast Tube. Ann. Biomed. Eng. 49, 2944–2956 (2021).
Roland, C. M. & Gamache, R. M. Measuring the Blast and Ballistic Performance of Armor: http://www.dtic.mil/docs/citations/AD1000449 (2015). https://doi.org/10.21236/AD1000449
Dale et al. A Methodology for Assessing Blast Protection in Explosive Ordnance Disposal Bomb Suits. Int. J. Occup. Saf. Ergon. 11, 347–361 (2005).
Needham, C. E., Ritzel, D., Rule, G. T., Wiri, S. & Young, L. Blast Testing Issues and TBI: Experimental Models That Lead to Wrong Conclusions. Front. Neurol. 6, 72 (2015).
European Commission. Joint Research Centre. Institute for the Protection and the Security of the Citizen. Calculation of Blast Loads for Application to Structural Components. Publications Office, LU, (2013).
Full Body Manikins. Safeguard Medical https://safeguardmedical.com/pages/simbodies#
EMS Torso Trainer. Safeguard Medical https://safeguardmedical.com/products/ems-torso-trainer
Gordon, C. et al. 2012 Anthropometric Survey of U.S. Army Personnel: Methods and Summary Statistics. (2014). https://dacowits.defense.gov/LinkClick.aspx?fileticket=EbsKcm6A10U%3D&portalid=48
Model 102B18 | PCB Piezotronics. https://www.pcb.com/products?m=102b18
Two Highcom 4S16 Multi Curve Level 4. Plates (Shooters or SAPI) (XS-XL) (6.2lbs). Apex Armor Solutions https://www.apexarmorsolutions.com/product-page/Two-Highcom-4S16-Multi-Curve-Level-4-Plates.
Sun, J. How to Size Yourself for Plate Carriers and Plates. Apex Armor Solutions (2023). https://www.apexarmorsolutions.com/post/how-to-size-yourself-for-plate-carriers-and-plates
UFC 3-340-02 Structures to Resist the Effects of Accidental Explosions. (2005).
Swisdak, M. M. Explosion Effects and Properties. Part I. Explosion Effects in Air. (1975). https://apps.dtic.mil/sti/citations/ADA018544
Model 137B23B | PCB Piezotronics. (2025). https://www.pcb.com/products?m=137b23b
Hi-Techniques - Synergy P | High Speed Data Acquisition. https://hi-techniques.com/products/synergy/p.html
Phantom v (2012).
Raffel, M. Background-oriented schlieren (BOS) techniques. Exp. Fluids. 56, 60 (2015).
BlastExposures, C., of, H. L. T. E., Populations, B. & on the on G. W. and H. of S. & Medicine, I. of. Pathophysiology of Blast Injury and Overview of Experimental Data. in Gulf War and Health, Volume 9: Long-Term Effects of Blast Exposures (National Academies Press (US), (2014).
Sutter, M. & Johnson, C. Preliminary Investigation of the Potential Health Risks of Non-Form-Fitting Body Armor with a Focus on Female Warfighter. Military Medicine https://doi.org/10.1093/milmed/usaf121 doi:10.1093/milmed/usaf121.
ASPIRE Hypersonic. Shockwaves. (n.d).
Teixeira, A. M. & Martins, P. A review of bioengineering techniques applied to breast tissue: Mechanical properties, tissue engineering and finite element analysis. Front Bioeng. Biotechnol 11, 1161815 (2023).
Acknowledgements
The authors of this paper want to acknowledge members of the Missouri University of Science and Technology Energetics Research Team for their assistance in completing the necessary experimentation. Funding for this work was through Army Research Laboratory (ARL) Award #W911NF-24-2-0093 as well as internal funds of Dr. Johnson at Missouri S&T.
Author information
Authors and Affiliations
Contributions
Melissa Sutter led the study design and experimental process and wrote the initial draft of the manuscript. Dr. Catherine Johnson assisted with the interpretation of the result, manuscript revision, and provided internal funding for the experiments performed. All authors reviewed and approved the final manuscript.
Corresponding author
Ethics declarations
Competing interests
The authors declare no competing interests.
Funding
Funding for this work was through Army Research Laboratory (ARL) Award #W911NF-24-2-0093 as well as internal funds of Dr. Johnson at Missouri S&T.
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Supplementary Information
Below is the link to the electronic supplementary material.
Rights and permissions
Open Access This article is licensed under a Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License, which permits any non-commercial use, sharing, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons licence, and indicate if you modified the licensed material. You do not have permission under this licence to share adapted material derived from this article or parts of it. The images or other third party material in this article are included in the article’s Creative Commons licence, unless indicated otherwise in a credit line to the material. If material is not included in the article’s Creative Commons licence and your intended use is not permitted by statutory regulation or exceeds the permitted use, you will need to obtain permission directly from the copyright holder. To view a copy of this licence, visit http://creativecommons.org/licenses/by-nc-nd/4.0/.
About this article
Cite this article
Sutter, M., Johnson, C. Sex-based effects of shock energy exposure in warfighters. Sci Rep (2026). https://doi.org/10.1038/s41598-026-47358-0
Received:
Accepted:
Published:
DOI: https://doi.org/10.1038/s41598-026-47358-0


