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Modular Scalable Vest

The Modular Scalable Vest (MSV) is a lightweight, modular body armor system developed for the United States Army as part of the Soldier Protection System (SPS), providing scalable protection that can be configured for low-profile concealable wear under uniforms or as a full tactical outer carrier with ballistic plates.^[1]^[2] Approved and introduced in 2018, it replaces the heavier Improved Outer Tactical Vest (IOTV) to enhance soldier mobility, fit, and mission adaptability while maintaining or improving ballistic resistance.^[3] The MSV's design emphasizes modularity and tailorability, enabling rapid adjustments between configurations for diverse operational needs, such as close-quarters engagement or extended patrols, without requiring multiple specialized vests.^[1] It incorporates soft armor panels and provisions for hard plates, with components like the concealable carrier and outer vest that integrate seamlessly with other SPS elements, including ballistic combat shirts and belts.^[2] Weighing approximately 26% less than the Improved Outer Tactical Vest (IOTV) when fully equipped, providing a weight reduction of about 10 pounds (4.5 kg), the MSV improves endurance in dynamic environments while offering a broader size range to accommodate diverse body types, including female soldiers.^[1]^[4] Subsequent iterations, such as the MSV Generation II, further refine these features with enhanced concealable options and compatibility with tactical blouses. As of 2025, the Generation II variant is the primary version in service, with recent enhancements including integration of lighter small arms protective plates.^[5]^[6] Overall, the MSV represents a significant advancement in personal protective equipment, prioritizing weight reduction, versatility, and user-centric design to support modern combat demands.^[3]

Background and Development

Origins and Requirements

The development of the Modular Scalable Vest (MSV) stemmed from the U.S. Army's experiences in post-2000s conflicts in Iraq and Afghanistan, where earlier body armor systems like the Interceptor Body Armor (IBA), introduced in 1999, and its successor, the Improved Outer Tactical Vest (IOTV), fielded in 2007, imposed significant mobility limitations on soldiers. The IOTV, while providing enhanced protection over vital areas, weighed up to 30 pounds when fully loaded with soft armor, plates, and accessories, contributing to soldier fatigue and reduced agility during dismounted operations.^[7]^[8]^[9] In response, the U.S. Army initiated the Soldier Protection System (SPS) program, launched in 2013, to address these shortcomings by developing a lighter, more adaptable torso protection system weighing under 25 pounds when fully configured, thereby improving soldier mobility and endurance without compromising protection. The SPS emphasized modularity to allow customization based on mission profiles, with the MSV serving as its core vest component to replace the IOTV across all configurations. This shift was driven by operational feedback highlighting the need to balance protection against the physical demands of prolonged engagements, ultimately aiming to reduce overall cognitive and physical load on soldiers through decreased weight and better fit options.^[10]^[2]^[11] Key developmental milestones occurred between 2015 and 2017 under the oversight of the Program Executive Office Soldier (PEO Soldier), including prototype design, material testing, and soldier-in-the-loop evaluations to refine scalability and comfort. By 2017, field tests at installations like Fort Carson demonstrated the MSV's 26% weight reduction compared to the IOTV Gen III, confirming its viability for scalable configurations from concealable low-profile carriers to full tactical setups. The Program Executive Office Soldier prioritized integration with existing legacy components to accelerate adoption while focusing on ergonomic improvements to minimize heat stress and movement restrictions.^[1]^[10]^[7] The MSV was specifically engineered to counter threats from small arms fire and fragmentation, establishing a baseline of NIJ Level IIIA soft armor protection capable of defeating multiple handgun rounds such as 9mm and .357 Magnum, alongside fragmentation from conventional munitions with V50 ballistic limits exceeding 2,700 ft/sec for 2-grain right circular cylinders. Hard armor inserts were designed to handle rifle threats and indirect fire flechettes when added, ensuring the system addressed evolving battlefield risks identified in recent conflicts. This threat-focused approach, detailed in the 2018 MSV Purchase Description, underscored the Army's commitment to verifiable protection standards under the SPS framework.^[12]^[13]^[2]

Procurement Process

The procurement of the Modular Scalable Vest (MSV) occurred as part of the U.S. Army's Soldier Protection System (SPS) program, utilizing competitive acquisition processes to select vendors for development and production. A synopsis for the SPS Torso and Extremity Protection (TEP) component, including the MSV, was issued in 2015, outlining requirements for manufacturing carriers, soft armor ballistic packages, and related components through a competitive bidding framework managed by the Program Executive Office Soldier.^[14] Initial production contracts were awarded in 2018 to multiple vendors following evaluations under the SPS TEP requirements. KDH Defense Systems received contract extensions totaling nearly $85 million to deliver next-generation MSV systems and Blast Pelvic Protectors, enabling low-rate initial production and early fielding.^[15] Point Blank Enterprises was also awarded under the MSV indefinite-delivery/indefinite-quantity (IDIQ) framework, receiving delivery orders such as one valued at over $22 million for complete MSV Generation II systems.^[16] These awards supported the MSV as a lighter replacement for the Improved Outer Tactical Vest, focusing on scalable torso protection.^[17] In 2021, the Army issued its first delivery order to Hardwire LLC under the MSV program for lightweight small arms protective plates, marking a key expansion in component production with funding in the millions to integrate advanced ceramic and composite materials.^[18] Production scaled from low-rate initial efforts in 2018 to full-rate by 2020, with vendors like Bethel Industries delivering over 200,000 MSV Generation II systems since then to meet Army-wide demands.^[19] The Defense Logistics Agency further supported seamless transitions through innovative IDIQ contracts, including a $450 million award in 2025 across multiple vendors to sustain domestic production without gaps.^[20] Contract values emphasized cost-effective scalability, with individual delivery orders ranging from $31.5 million for core MSV units in 2019 to larger multi-year IDIQs supporting ongoing procurement.^[21] This approach prioritized rapid integration of modular components while adhering to Berry Amendment requirements for U.S.-sourced materials.^[17]

Design and Components

Core Structure and Materials

The base carrier of the Modular Scalable Vest (MSV) is constructed from nylon fabrics, such as 500 Denier Cordura, ensuring high durability, abrasion resistance, and flame-retardant properties suitable for demanding operational conditions. This construction incorporates laser-cut laminate panels reinforced with nylon webbing to reduce weight while preserving structural integrity.^[17]^[22]^[12] Soft armor inserts in the MSV consist of multi-layer aramid or ultra-high-molecular-weight polyethylene (UHMWPE) panels, which deliver NIJ Level IIIA protection specifically against handgun threats including 9mm and .44 Magnum rounds. These flexible panels are housed within the concealable carrier layer, allowing for low-profile wear under uniforms.^[22]^[23] Key integration points feature MOLLE/PALS-compatible webbing across the carrier for secure accessory mounting, Duraflex quick-release buckles for rapid donning and doffing, and adjustable shoulder and cummerbund straps to fit a range of body types from extra-small to extra-extra-large. The combined weight of the base carrier and soft armor inserts ranges from 8.5 to 11.8 pounds (3.9 to 5.3 kg), depending on size, and the system adheres to MIL-STD-810 testing protocols for resistance to environmental stresses like temperature extremes, humidity, and shock.^[17]^[24]^[23]^[12]

Modularity Features

The Modular Scalable Vest (MSV) employs a quick-don/doff system featuring a multi-point buckle mechanism that enables rapid assembly and removal, operable from the left shoulder, right shoulder, or both sides for accessibility in emergency or rollover scenarios. This design simplifies the process compared to the Improved Outer Tactical Vest (IOTV), supporting efficient reconfiguration by soldiers.^[10] Attachment systems on the MSV include a standardized MOLLE-compatible grid for securing pouches and mission-essential gear, supplemented by laser-cut slots that replace heavier traditional PALS webbing to minimize overall weight. Side panels accommodate optional side ballistic inserts, while an adjustable cummerbund provides torso sizing and integrates with these components for secure fit. The vest utilizes continuous extruded hook fastener tape, such as Velcro Brand equivalents, for reliable interfaces in assembly and attachments.^[10]^[9]^[12] Customization options allow tool-free addition or removal of side armor panels, shoulder pads, and load-bearing equipment, permitting soldiers to tailor the vest to varying mission profiles without specialized tools. This modularity ensures adaptability while maintaining structural integrity across configurations.^[9] Ergonomic enhancements in the MSV include a padded back yoke for distributed weight loading and a cummerbund that transfers load to the hips, reducing strain on the shoulders during prolonged use. Adjustable straps and extended sizing options support fit for both male and female soldiers, improving comfort, range of motion, and overall performance in dynamic environments.^[10]

Protection and Performance

Ballistic Capabilities

The soft armor panels in the Modular Scalable Vest are certified to NIJ Standard-0101.06 Level IIIA, providing protection against handgun threats including 9mm full metal jacket (FMJ) rounds fired at velocities up to 1,400 ft/s and .44 Magnum semi-jacketed hollow point (SJHP) rounds at 1,400 ft/s.^[25]^[13] The vest integrates Enhanced Small Arms Protective Insert (ESAPI) and X-Threat Small Arms Protective Insert (XSAPI) hard armor plates, constructed from ceramic strike faces backed by composite materials, which defeat 7.62mm armor-piercing rounds at velocities of 2,780 ft/s while maintaining multi-hit capability for six or more impacts.^[2] Fragmentation resistance is achieved through the soft armor and plate configurations, providing protection against shrapnel and debris common in explosive environments. Testing protocols for the MSV comply with NIJ Standard-0101.06, limiting backface deformation to no more than 44 mm to minimize blunt trauma from non-penetrating impacts.^[25]

Scalability Options

The Modular Scalable Vest (MSV) features a four-tier configuration system that enables soldiers to adjust protection levels and weight according to mission requirements and threat environments, enhancing operational flexibility.^[10] This scalability allows commanders to tailor the vest from minimal setups for low-threat scenarios to comprehensive armor for high-intensity combat, reducing overall system weight by approximately 5 pounds compared to the Improved Outer Tactical Vest (IOTV) when fully loaded.^[10]^[7] In low-profile mode, corresponding to Tier 1, the MSV uses a concealable carrier with soft armor only, designed for urban or covert operations where discretion is prioritized; this configuration weighs around 11 pounds for a medium size and can be worn under uniforms without detection.^[10]^[1] For full tactical mode, or Tier 4, the system incorporates the outer carrier with Enhanced Small Arms Protective Insert (ESAPI) plates, side panels for lateral coverage, and additional components like the ballistic combat shirt for neck and shoulder protection, plus a blast pelvic protector and load-distributing belt; this setup reaches up to 25 pounds but provides equivalent ballistic performance to the IOTV while improving weight distribution to the hips.^[10]^[7] Intermediate scaling options, represented by Tiers 2 and 3, offer balanced configurations such as soft armor augmented with ballistic plates for core torso protection or partial side coverage, allowing soldiers to maintain mobility in medium-threat environments without the full weight burden of complete armor.^[10] These tiers facilitate quick adjustments in the field, with removable soft armor panels and plate pockets enabling reconfiguration based on evolving mission profiles.^[10] For mission-specific roles, the MSV integrates with specialized torso protection kits, such as those enhancing mobility and center-of-gravity balance for explosive ordnance disposal (EOD) operations, where the vest's modular design supports added equipment without excessive upper-body strain.^[26] Similar adaptations apply to medical personnel, incorporating partial coverage options to accommodate medical kits while preserving essential ballistic safeguards against fragmentation and small-arms threats.^[7] This versatility ensures the MSV meets National Institute of Justice standards for configurable protection across diverse scenarios.^[7]

Variants and Upgrades

Generation I

The Generation I Modular Scalable Vest (MSV) was fielded to U.S. Army units beginning in the summer of 2018 as the baseline component of the Soldier Protection System (SPS), marking the first major update to body armor in over a decade.^[27] Designed to replace the Improved Outer Tactical Vest (IOTV), the MSV emphasized enhanced mobility, scalability, and adaptability for various mission profiles while maintaining ballistic protection standards.^[28] Initial fielding prioritized close combat units, with the vest configured for both concealable soft armor and plate carrier modes to support a range of operational needs.^[29] Key specifications of the Generation I MSV included a fully configured weight of approximately 25 pounds (11 kg), about 5 pounds (2.3 kg) lighter than the IOTV, representing up to a 26% reduction in certain configurations, achieved through advanced materials like ultra-high-molecular-weight polyethylene (UHMWPE).^[8]^[10]^[28] This weight savings improved soldier endurance during extended wear without compromising protection against small arms fire and fragmentation. The vest offered multiple sizing options, including six core unisex sizes (extra small to extra-extra large) plus expanded variants such as short and long configurations, enabling better fit across diverse body types and reducing coverage gaps. These features allowed for tailoring to individual soldiers, with adjustability in shoulder straps, cummerbunds, and side panels to optimize comfort and load distribution.^[10] Early iterations revealed minor issues during 2019 user evaluations, particularly regarding fit for female and smaller-statured soldiers, where adjustments were recommended to refine torso coverage and prevent chafing.^[30] Heat dissipation was also noted as an area for improvement in prolonged wear scenarios, with feedback highlighting the need for enhanced ventilation in high-temperature environments to mitigate thermal stress.^[17] These observations stemmed from field trials involving diverse soldier demographics, informing iterative refinements while the vest remained operational.^[31] Production of the Generation I MSV ramped up through multiple contracts awarded by the U.S. Army, with Point Blank Enterprises serving as a primary manufacturer responsible for delivering systems and components.^[32] A major contract was awarded in December 2020 with a ceiling value exceeding $600 million, supporting widespread issuance across Army units as the SPS baseline.^[16] The vest's modular design facilitated efficient manufacturing, with domestic production ensuring compliance with Berry Amendment requirements for U.S.-sourced materials.^[17]

Generation II

The Modular Scalable Vest Generation II (MSV Gen II) began early fielding by the U.S. Army in late 2021 as an iterative upgrade to the original system, featuring significantly faster assembly times—reducing reconfiguration from minutes required by the predecessor Improved Outer Tactical Vest to mere seconds—along with refined concealable components for enhanced low-profile wear.^[23] Key upgrades in the MSV Gen II include an enhanced quick-release system utilizing replaceable buckles for rapid donning and doffing, integrated ventilation mesh via the Quad Ventilation Liner (QVL) for improved airflow and heat dissipation, and a branch-specific variant for the U.S. Air Force. The Air Force adaptation, known as the QR2 plate carrier developed by Armor Express, meets National Institute of Justice (NIJ) Level IIIA standards while maintaining compatibility with the MSV's user interface and visual profile for seamless integration.^[35]^[36]^[13] Adaptations for specialized roles emphasize a lighter low-visibility (low-vis) carrier configuration, scalable from the base modularity to support special operations with reduced bulk and improved mobility under clothing. Commercial offerings of the MSV Gen II, such as those from Armor Express, include a 30-day return policy to facilitate unit-level procurement and testing.^[37] Development of the MSV Gen II involved operational testing starting in late 2021, with initial feedback addressing weight distribution issues from the Generation I model through refined load-bearing elements. Fielding continues as of 2025, with over 80,000 MSV systems issued across generations by late 2024 and integration with new lightweight small arms protective inserts under recent contracts.^[38]^[39]^[40]^[6]

Operational Use

Military Adoption

The United States Army adopted the Modular Scalable Vest (MSV) as its primary body armor system starting in 2018, replacing the Improved Outer Tactical Vest to enhance soldier mobility and protection. Initial fielding occurred that year as part of the Soldier Protection System, with approximately 80,000 units distributed to close combat units as of 2024, and continued fielding through 2025.^[40]^[20] By 2021, the MSV had been equipped to infantry brigades, including the 82nd Airborne Division, where soldiers received tailored fittings during deployment preparations. Special operations forces, influenced by earlier systems like the Adaptive Vest System, have shown interest in scalable designs similar to the MSV for mission requirements.^[41] The U.S. Air Force began adopting an MSV Generation II equivalent in 2021 through the Air Force Security Forces Center, focusing on security forces with a modular design adapted for airmen needs. In 2023, the service advanced this with the QR2 system, a NIJ Level IIIA counterpart to the MSV Gen II, providing faster delivery and weight reductions for immediate unit availability.^[13] The U.S. Marine Corps has implemented partial use of similar scalable systems, such as the Improved Modular Tactical Vest and Plate Carrier variants, incorporating modularity features akin to the MSV without full adoption of the Army's model. Training integration for the MSV became standardized post-2019, with mandatory fit assessments and reconfiguration drills incorporated into basic and advanced individual training to ensure proper sizing and adaptability. These protocols emphasize quick adjustments for mission-specific configurations, supporting the vest's scalability across roles. International adoption remains limited, with no verified exports of the MSV under Foreign Military Sales programs to allies like the United Kingdom or Australia as of 2025.

Field Evaluations

Field evaluations of the Modular Scalable Vest (MSV), including initial trials at bases like Fort Carson, revealed positive soldier feedback on improved mobility compared to the Improved Outer Tactical Vest (IOTV).^[10] These assessments involved operational simulations and user input, emphasizing the vest's lighter weight and adjustable fit as key factors enhancing range of motion during extended wear.^[42] User feedback underscored the MSV's scalability as a major strength, allowing rapid adjustments for diverse mission profiles, from low-profile reconnaissance to full tactical engagements, which soldiers praised for versatility in real-world scenarios.^[1] In 2024-2025 updates, evaluations of the Generation II MSV focused on ballistic performance and fielding progress, with ongoing studies including biomechanical analyses and user trials to assess enhancements like improved thermal regulation while maintaining protection levels equivalent to NIJ standards.^[43]

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