Optimizing The MOLLE For The Female Soldier
Optimizing the MOLLE forthe Female SoldierA Major Qualifying Project submitted to the Faculty of WorcesterPolytechnic Institute in partial fulfillment of requirements of theDegree of Bachelor ScienceBy:Amy BabeuErin LaRocheRachael MattyMarlisa (Cardoso) OvertonAdvisors:Karen TroyDate:1 May 2014
Table of ContentsTable of Figures . 3Table of Tables . 5Authorship. 6Acknowledgments . 7Abstract . 8Chapter 1: Introduction . 9Chapter 2: Literature Review . 112.1 Evolution of U.S. Army Load Carrying Equipment . 112.1.1 MLCE . 112.1.2 ALICE . 122.1.3 Current Model: MOLLE . 142.2 Male vs. Female Anatomy Affecting Load Carriage . 192.2.1 Skeletal Differences . 202.2.2 Muscular Differences . 202.3 Load Distribution . 202.4 Commercial Backpacks for Females . 222.5 Previous Studies. 232.6 Patents. 262.6.1 Shockproof Quick-Release Fastener for an End Fitting of a Safety Belt . 262.6.2 Modular Load Carrying Equipment . 262.6.3 Quick-Release Weight Distribution and Connection System . 262.6.4 Adaptive Fit Waist Belt and Backpack Having Such a Waist Belt . 27Chapter 3: Project Strategy . 283.1 Initial Client Statement. 283.2 Design Objectives . 283.3 Constraints. 303.4 Revised Client Statement . 313.5 Project Approach . 313.5.1 Design Testing . 313.5.2 Subject Testing. 323.5.3 Management . 333.5.4 Finances. 35Chapter 4: Design Alternatives . 374.1 Needs analysis . 374.2 Functions . 374.2.1 Specifications: . 394.3 Alternative Designs . 404.3.1 Fastener Alternatives. 404.3.2 Tightening Alternatives . 424.3.3 Padding Alternatives . 431
4.3.4 Additional Design Aspects . 464.4 Final Selection Matrix . 474.5 Conceptual Design . 494.5.1 Initial prototype . 504.5.2 Final prototype . 534.5.3 Final Design . 554.6 Feasibility . 574.7 Preliminary Data . 584.7.1 Compression Testing of Materials for Padding . 584.7.2 Tension Testing of Buckles . 614.7.3 Body Measurements . 64Chapter 5 Raw Data . 675.1 Obstacle Course . 675.1.1 Rate of Perceived Exertion. 705.1.2 User Survey. 735.1.3 Heart Rate . 755.2 Force Plate . 775.3 Pressure Film . 79Chapter 6: Discussion . 856.1 Discussion of Results . 856.2 Testing Limitations . 876.3 Discussion of Impact of Hip Belt . 886.3.1 Economics . 886.3.2 Environmental Impact . 886.3.3 Social Influence . 886.3.4 Political Ramifications . 896.3.5 Ethical concern. 896.3.6 Health and Safety Issues . 896.3.7 Manufacturability . 906.3.8 Sustainability . 90Chapter 7: Final Design and Validation. 91Chapter 8: Conclusion and Recommendations . 95References . 97Appendix A: Complete IRB Form . 100Appendix B: Sewing Patterns . 107Appendix C: Heart Rate Data . 111Appendix D: Pressure Film . 117Appendix E: Public Awareness . 1212
Table of FiguresFigure 1: Pouch Attachment Ladder System . 15Figure 2: Hip Belt Connector to Ruck Frame . 16Figure 3: Components of the MOLLE II System . 17Figure 4: MOLLE II Molded Hip Belt . 18Figure 5: Placement of Load in the Backpack . 21Figure 6: Work Breakdown Structure . 34Figure 7: Gantt Chart . 35Figure 8: A) Hook and Eye, B) Twist Closure, C) Threaded Hook Closure. 40Figure 9: Seatbelt Closure . 41Figure 10: A) Front Release Buckle, B) Side Release Buckle . 41Figure 11: One Strap Tightening System . 42Figure 12: Offset Attachment Strap Tightening System . 43Figure 13: Horizontal Padding . 44Figure 14: Elastic Edging . 44Figure 15: Webbing Attached Padding . 45Figure 16: Split Padding . 46Figure 17: Additional Straps for Frame . 46Figure 18: Initial Prototype - a) Front View b) Back View c) Over Head View d) InsideView . 50Figure 19: Anatomic Features of Pelvic Girdle that Cause Pressure Problems withCurrent MOLLE Hip Belt . 51Figure 20: Padding With Open Cut . 52Figure 21: Prototype Sketch . 53Figure 22: Final Prototype a) Front View b) Back View c) Side View d) Buckle View . 54Figure 23: Final Design a) Inside View b) Front View c) Side View . 56Figure 24: Final Design with Modifications A) Front View B) Side View. 57Figure 25: Compression Testing Setup . 59Figure 26: Compression Test of Current Model . 60Figure 27: Tension Testing Setup . 61Figure 28: Failure of Side Release Buckle . 62Figure 29: Failure of Center Release Buckle . 63Figure 30: Obstacle Course Route Map . 68Figure 31: Chart Used by Participants to Measure RPE . 71Figure 32: Rate of Perceived Exertion Results . 73Figure 33: Results of Survey Questions . 75Figure 34: Participant 4 Heart Rate Data . 76Figure 35: Participant 10 Heart Rate Data . 76Figure 36: COP Path Length (cm) for 10 Seconds . 77Figure 37: COP Path Length (cm) for 5 Seconds . 78Figure 38: Placement of Pressure Film A) shoulders B) Superior Anterior Iliac Spine C)Superior Posterior Iliac Spine . 79Figure 39: Pressure Film Preparations . 803
Figure 40: Pressure Film From Iliac Crest A) Old Belt B) New Belt . 81Figure 41: Pressure Film from Posterior Superior Iliac Spine A) Old Belt B) New Belt. 83Figure 42: Pressure Film From Shoulders A, C) Old Belt B,D)New Belt . 84Figure 43: Shell Pattern .107Figure 44:Back Padding Pattern (Mesh Part) .107Figure 45:Back Padding Pattern (Codura Part) .108Figure 46: Velcro Pattern for Padding Backing .109Figure 47: Padding Pattern.109Figure 48: Padding Pattern for Fabric Cover .110Figure 49: Participant 1 Heart Rate Data .111Figure 50: Participant 2 Heart Rate Data .111Figure 51: Participant 3 Heart Rate Data .112Figure 52: Participant 4 Heart Rate Data .113Figure 53: Participant 5 Heart Rate Data .113Figure 54: Participant 6 Heart Rate Data .114Figure 55: Participant 7 Heart Rate Data .114Figure 56: Participant 8 Heart Rate Data .115Figure 57: Participant 9 Heart Rate Data .115Figure 58: Participant 10 Heart Rate Data .116Figure 59: Participant 1 Pressure Film .117Figure 60: Participant 2 Pressure Film .118Figure 61: Participant 3 Pressure Film .119Figure 62: Participant 4 Pressure Film .1204
Table of TablesTable 1: Pairwise Comparison Chart . 29Table 2: Financial Breakdown for Client . 36Table 3: Function Means Chart . 39Table 4: Fastener Design . 47Table 5: Tightening Design . 48Table 6: Padding Design. 48Table 7: Additional Design Aspects. 49Table 8: Body Measurements. 65Table 9: Overview of Study Participants . 70Table 10: Results of RPE Survey Questions . 72Table 11: Summary of Survey Results . 75Table 12: COP Path Length (cm) for 10 Seconds under Various Conditions. 77Table 13: COP Path Length (cm) for 5 Seconds Under Various Conditions . 78Table 14: Pressure Film Size . 80Table 15: Histogram Summary for Anterior Superior Iliac Spine . 82Table 16: Histogram Summary for Posterior Superior Iliac Spine . 83Table 17: Histogram Summary for Shoulders . 845
AuthorshipAll members of the team contributed equally to the success of this project.6
AcknowledgmentsThe team would like to give special thanks to Natick Soldier Systems Center, andespecially Mr. Richard Landry, for providing our team with the materials, tools, and spaceto design and build our final product. The team is grateful for Mr. Landry’s help andunwavering support for the project. The team would also like to thank all test subjects fortheir assistance with this project. Lastly, the team would like to thank our advisor, ProfessorKaren Troy, for her guidance and support throughout the duration of the project.7
AbstractAs female Soldiers become more prevalent in the U.S. military, it is becomingincreasingly important to address the physical differences that may limit theirperformance in the field. The purpose of this project was to design a female specific hipbelt for the MOLLE system that complies with the United States Army standards toeffectively distribute the load on the body while allowing the Soldier to complete allnecessary tasks that occur in the field. The team developed a new hip belt with wingedpadding attached to an outer shell. Various modifications were made to increase thecomfort and ease of adjustability of the belt. To validate the design, the team performedvarious tests including an obstacle course, which included survey questions, and pressurefilm testing. The results of the team’s tests showed that their modified hip belt was animprovement from the current model in that it distributed the weight more evenly acrossthe user’s hips and provided more comfort for the user.8
Chapter 1: IntroductionA Soldier’s individual combat equipment, the gear he or she is required to haveon person for mission success, has always been an essential part of the of the footSoldier’s burden. Over time, load-bearing equipment has evolved and the Army hasadopted new models to address the needs and demands of the modern Soldier. Thecurrent load-bearing equipment, designed with male physical characteristics in mind, iscalled the Modular Lightweight Load-carrying Equipment (MOLLE) rucksack, which iscomprised of a plastic frame and various detachable pouches that can be adjusted todistribute weight for the user’s comfort. However, this design can cause discomfort orinjury to women, who have different structural features than men. As women areaccepted into more combat roles, it is necessary to take into account the physicaldifferences of the female SoldierDifferences in the skeletal and muscular systems influence how males andfemales carry backpacks and other loads. The pelvis of the female is wider and lower inthe body, allowing her to carry more weight in the hips. The female bones are alsosmaller and less dense than male bones. Males also have greater upper body strength dueto greater muscle mass in the torso and shoulders. Due to these differences, femalesprefer to carry loads differently than males.Many studies have been conducted on the effects of backpack loads on females.These studies have used various loads or torso angles to observe how these changes affectthe load carriage of rucksacks. By varying the conditions, researchers are able to measuremuscle activity, center of pressure, and load distribution. These tests have confirmed thatfemales carrying heavy loads are more susceptible to injury and wearing a hip belt isbeneficial for weight distribution. However, not all female Soldiers choose to wear thehip belt provided on the MOLLE.The amount of load that a Soldier carries in his or her rucksack has been steadilyincreasing throughout history, and the manner in which this load is distributed in thebackpack greatly influences the energy expenditure of the Soldier, as well as his or herperformance in the field. The most practical way to carry load is as close to the center of9
mass (COM) of the body as possible. In order to maintain COM of the body, Soldiers canuse a double pack that evenly distributes the weight in the back and front of the body, butthis design has limitations. To compensate for these limitations, modifications to thebackpack, such as hip belts and shoulder straps, have been designed. These additionsallow for more efficient distribution of load to maintain the COM of the body. However,it is difficult for women to appreciate the benefits of these modifications as they wereoriginally designed based on the physical characteristics of men. Often times, womencannot perform as well as men in training and in combat due to their lower upper bodyand torso strength. Consequently, their COM is different than men, and they prefer tocarry loads closer to their hips. Improper fit of the hip belt may cause discomfort ormusculoskeletal problems (Ling et. al, 2004). This discomfort and injury among femaleSoldiers drives the growing need to develop modifications for the MOLLE.10
Chapter 2: Literature Review2.1 Evolution of U.S. Army Load Carrying EquipmentA Soldier’s individual combat equipment, the gear he is required to have on hisperson for mission success, has always been an essential part of the of the infantry man’sburden. This individual combat equipment has been referred to by many names over thecourse of military history and has evolved over time to better meet the needs anddemands of the American Soldier. The Soldier’s most common term for this equipment,from World War I to present, is “web gear.” Today, it can also be referred to as loadcarrying equipment (LCE) or load bearing equipment (LBE). Regardless of the name, aSoldier’s gear is absolutely essential to survival and mission success. Once issued, thisgear becomes part of the Soldier. It does not escape his person, and if doffed, alwaysremains within arms reach.Since the introduction of the first modern load carrying equipment system, thedevelopment of US Army load carrying equipment has taken off. The military has itsown employees that work solely on the development of new equipment for Soldiers.Many of the major changes in load carrying impact have been implemented for theadoption of new weapon systems and the necessity to carry their ammunition. There areseveral factors that have a direct impact on the development of new load carryingequipment including materials used, physiological, or “comfort,” factor, and the trade-offbetween lightweight and durability. The search for the indefinable “light load” may neverend, as improvements are always to be made. A balance must be found in designinglightweight gear that does not sacrifice durability. Lightweight gear permits Soldiersgreater efficiency by allowing a greater freedom of movement. New designs of loadcarrying equipment seek to improve agility and comfort, but weight is ultimately the keyfactor leading the design (Rottman, 1989).2.1.1 MLCEThe M1967 modernized load carrying equipment, or MLCE, was designedspecifically for use in the Vietnam War. The MLCE was the first generation ofmodernized load carrying system adopted by the Army. The MLCE had essentially the11
components of the previous design, but substituted nylon for cotton, and aluminum andplastic in place of steel and brass hardware wherever possible. The design of the 1967MLCE tropical rucksack was influenced by the indigenous rucksack of the SpecialForces-advised Civilian Irregular Defense Group (CIDG) in Vietnam. Captured NorthVietnamese Army rucksacks were sent to counter-insurgency to be used as models in theearly 1960s. The MLCE rucksack issued to the US Army was created using theseVietnamese rucksacks as a model (Rottman, 1989).The MLCE model had three large cargo packets and equipment loops attached tothe side and the back. The rucksack pockets were sewn only on the sides to allow amachete to be attached to a loop and positioned under the pocket. The main pouch of therucksack was fashioned with a drawstring. Likewise, the three rubberized fabricwaterproof liners were also fashioned with a drawstring. The top flap of the rucksack wassecured by two straps and contained a thin rubberized fabric-lined pocket. The fabric,made of nylon, was lightweight and durable, which was one of the main qualities that ledto the US Army’s consideration of the MLCE for Army-wide adoption. The
Soldier’s burden. Over time, load-bearing equipment has evolved and the Army has adopted new models to address the needs and demands of the modern Soldier. The current load-bearing equipment, designed with male physical characteristics in mind, is called the Modular Lightweight Load-carrying Equipment (MOLLE) rucksack, which is
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RESCUE SWIMMER VEST - MOLLE POCKET ATTACHMENT USA: MA0098 CAN: MA0098 Compatible with Rescue Vests and other MOLLE-bearing products. See full details on page 17. RESCUE SWIMMER VEST - MOLLE POCKET ATTACHMENT USA: MA0099 CAN: MA0099 Compatible with Rescue Vests and other MOLLE-bearing producst. See full details on page 17. SIZE Universal Adult
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