# EUC ARMORED VEST — Tech pack v0.1 (prototype build)

Front-zip compression vest with a stand collar. Carries the full back protector, split chest pads and two shoulder caps on docks; five welded cooling panels; four fan pods; the manifold block with pinch valves and the vest hub board. Snaps into the capri waistband (it is the suspender). Fidlock receivers at both armholes for the sleeves.

Material codes F1–F11, H1–H6, T1–T2, A1 are the capri's. New codes below. Base body as the capri pack; regrade from section 1.

---

## 1. Measurements

| # | Point | Where | Base (mm) |
|---|---|---|---|
| M20 | Chest | at the nipple line | 1040 |
| M21 | Ribs | at the bottom of the sternum | 940 |
| M1 | Waist | at navel (capri) | 865 |
| M22 | Shoulder width | acromion to acromion, across the back | 470 |
| M23 | Neck | base of neck | 400 |
| M24 | Back length | C7 to waist | 480 |
| M25 | Front length | collarbone notch to waist | 400 |
| M26 | Armhole | around the shoulder joint through the armpit | 480 |

Negative ease: chest −10%, ribs −12%, waist −8% (must match the capri), armhole −5%. Neck 0% — the collar is snug, never compressive; the collar panel does the cooling, not pressure on the carotids. Collar height 60 mm.

---

## 2. Materials (new codes)

| Code | Material | Use |
|---|---|---|
| F12 | 3D spacer mesh, 5 mm, warp-knit | Plenums under the back and chest laminates, skin side |
| F13 | Woven power elastic 40 mm with six 15 mm snap studs | Hem band |
| H7 | Fidlock SNAP receivers (female), 8 | Armhole bands, 4 per side |
| H8 | YKK AquaGuard #5, 2-way, 500 mm | Front zip |
| H9 | Fan pod: 30 × 4 mm blower, printed housing with snap ring and intake screen, JST-PH lead 250 mm, 4 | Side seams ×2, lower back ×2 |
| H10 | Manifold block: 7 + 7 ports 4 mm push-in, two pinch-valve seats, hub board mount | Lower back |
| H11 | Vest hub board: SHT31, 2 valve drivers, 4 fan outputs, 6-pin JST-XH lead 200 mm | On H10 |
| H12 | Pinch valves, 12 V, 4 mm tube, 2 | On H10, chest pair and back pair supply |
| C1, C2 | Cooling panel, chest, 200 × 140 | Below the chest pads |
| C3, C4 | Cooling panel, back, 240 × 110 | Beside the back protector |
| C5 | Cooling panel, collar, 380 × 50 curved | Inside the collar |
| P5 | Back protector, SAS-TEC Level 2 EN 1621-2 full back with wings, ~460 × 300 | V1 |
| P6 | Chest, Level 2 EN 1621-3 split pair, ~180 × 120 each | V2 |
| P7 | Shoulder cap, Level 2 EN 1621-1, ~150 × 110 | V3 |

Cooling panels, v0: cold-therapy replacement pads (back and shoulder shapes) with their barbs swapped for 4 mm. v1: RF-welded 0.25 mm TPU, 8 mm channels on 12 mm centers, quilt welds every 30 mm, two welded 4 mm barbs on the port edge.

---

## 3. Dock and module map

| Dock | Pad | Center | Laminate (W × L) | Rails c-c | Rail length | Stop end |
|---|---|---|---|---|---|---|
| V1 back | P5 | spine, top edge 30 mm below C7 | 320 × 480 | 120 | 280 | top (neck). Backward falls slide feet-first and drag the pad toward the head. Pad enters from below. |
| V2 chest L/R | P6 | over each pectoral, 40 mm below the collarbone, 30 mm off the sternum | 130 × 190 | 70 | 130 | bottom. Pad enters from the collar. |
| V3 shoulder L/R | P7 | acromion, wrapping 40 mm onto the deltoid | 120 × 160 | 60 | 100 | neck end. Rails run acromion → neck. Pad enters from the point of the shoulder. |

Cooling panels (inside face, in bonded F3 mesh sleeves, port edge open toward the nearest side seam):
- C1/C2: from the bottom of the sternum to 20 mm above the hem, 20 mm off the centerline, under the pectoral pads, never under them.
- C3/C4: 20 mm outboard of the V1 laminate, from the bottom of the scapula wings to 20 mm above the hem.
- C5: inside the collar, ports at center back.

Fans: two pods at the side seams at rib height, intake through a 40 mm laser-perforated window in the side panel, pushing into the chest plenum. Two pods at the lower back, 80 mm above the hem, pushing up the spine plenum. Exhaust at the collar seam. Plenums are F12 under the V1 and V2 laminates only, extending to the pods.

Manifold block: center back, 40 mm above the hem, below the V1 laminate. Supply manifold left, return right. Pinch valves on the chest-pair and back-pair supply lines. Two dry-break tails exit the hem at center back, 150 mm, plus the 6-pin lead. Wrist lines: from the supply and return manifolds along both side seams inside a bonded tape channel to a dry-break pair at each armhole band, 6 o'clock position.

---

## 4. Pattern pieces

Cut 2 of each side piece (mirror). 6 mm allowance on flatlock seams, 0 on bound edges.

| Piece | Fabric | Description |
|---|---|---|
| V-P1 Front L/R | F1 | Zip edge to side seam, collar seam to hem. Carries V2 and V3 laminates (V3 spans the shoulder seam: bond it after the shoulder seam is sewn). |
| V-P2 Side L/R | F1 | 90 mm wide, armpit to hem. 40 mm perforated intake window at rib height. Carries a fan pod. Wrist-line tape channel on the inside. |
| V-P3 Back | F1 | One piece, collar to hem. Carries V1 laminate and, below it, the manifold block mount (bar-tacked F10 patch 80 × 60). |
| V-P4 Collar | F1 doubled | 60 mm stand, with an inside sleeve for C5, ports at CB. |
| V-P5 Hem band | F13 | Studs at CF ±60, both side seams, CB ±60. Dry-break and lead grommets (H4) at CB between the studs. |
| V-P6 Armhole band L/R | F1 doubled, 40 mm | Four H7 receivers at 12 / 3 / 6 / 9. Dry-break pair at 6. |
| V-P7 Zip facing L/R | F1 | 30 mm, backs the AquaGuard zip. |
| V-P8 Panel sleeves ×5 | F3 | Mesh pocket bonded to the inside face, sized to the panel + 8 mm, open on the port edge with a 20 mm gripper strip inside the opening. |
| V-P9 Plenum ×3 | F12 | Under V1 (one piece, 300 × 460) and V2 (two, 120 × 180), skin side, bonded at the perimeter only. |
| V-D1, V-D2 ×2, V-D3 ×2 | F4 + F5 + F6 | Laminates per section 3. |

Seams: 4-thread flatlock, T1. Bonded first wherever a seam meets a laminate edge. Bar-tacks at every snap, receiver, grommet and pod mount. No seam crosses a laminate. The side seam carries the pod and the intake window, so it is a bonded seam, not a flatlock.

---

## 5. Interfaces

- Hem: six studs into the capri waistband sockets. Load path: waistband → snaps → vest → shoulders.
- Armholes: four Fidlock receivers per side; the sleeve's four males snap in. Dry-break pair at 6 o'clock, females on the vest.
- Fluid: two dry-breaks at CB hem to the puck.
- Electrical: one 6-pin lead at CB hem to the puck. Pinout in the platform map.

---

## 6. Construction order

1. Bond V-D1, V-D2, V-D3 laminates and their rails per capri section 6 (rails: V1 stop-up, V2 stop-down, V3 stop toward the neck). Bind, gripper.
2. Sew shoulder seams on the donor or cut pieces; bond V-D3 across them. Bond V-D2 to fronts, V-D1 to back.
3. Bond F12 plenums under V1 and V2 on the inside face, perimeter only, leaving the pod-side edge open.
4. Sew side panels with the intake windows and the wrist-line tape channels. Mount fan pods (snap ring through a 32 mm hole, bar-tacked keeper).
5. Bond the five panel sleeves to the inside face. Insert panels, route 4 mm tubes to the manifold block along the inside of the side seams and the hem.
6. Mount the manifold block on its patch; fit pinch valves and the hub board; connect fan leads.
7. Collar with C5 sleeve; zip and facings; armhole bands with receivers and dry-breaks; hem band with studs and grommets.
8. Dock pads. Snap to the capri. Fit.

---

## 7. Tests

- Leak: with all panels connected and the dry-breaks capped, 0.3 bar for 30 minutes, dry paper towel under every port. No exceptions before it touches a body.
- Dock retention: 5 kg pull, four directions, per pad.
- Fan flow: tissue held at the collar seam lifts with all four pods at 100%.
- Fit: zip closed, 30 minutes standing; the back protector top edge stays below C7 when you look down; the chest pads don't ride onto the collarbones when you raise your arms.
- Boost routing: with the valves closed, collar and wrist lines take visibly more flow (bath water dyed, 10 seconds).

---

## 8. BOM (one vest, proto)

| Item | Qty |
|---|---|
| F1 body knit | 1.2 m |
| F3 vent mesh | 0.4 m |
| F4 UHMWPE, F5 aramid felt, F6 film | 0.3 m each + film for rails |
| F12 spacer mesh | 0.4 m |
| F13 hem band + 6 studs | 1.0 m |
| H7 Fidlock receivers | 8 |
| H8 zip | 1 |
| H9 fan pods | 4 |
| H10 manifold block, H11 hub board, H12 valves | 1, 1, 2 |
| H5 dry-breaks | 2 pair CB + 2 pair armholes |
| 4 mm PU tube + push-ins | 6 m, 20 |
| C1–C5 | 5 (v0: 2 back pads + 2 shoulder pads + 1 collar improvised from a universal pad) |
| P5, P6, P7 | 1, 2, 2 |
| Rails, carriers | print from the SCAD: back, chest ×2, shoulder ×2 |

---

## 9. Open decisions

1. Your M20–M26.
2. Back protector model — envelope drives V-D1 and the rail length.
3. Collar panel on the boost path by default (yes in this pack).