Client
Regional UK Police Force
Challenge
Incompatible legacy vests for new body-cam and radio rollout.
Solution
Bespoke load-bearing vest, designed and prototyped in the UK.
Core Services
Consultation, UK Prototyping, Flexible Manufacturing
A regional UK police force was preparing for a force-wide rollout of new, essential technology: a state-of-the-art body-worn video camera and a new digital radio system. They immediately hit a critical roadblock: the new equipment was incompatible with their existing load-bearing vests. The pouches didn't fit, the cable routing was insecure, and the new weight distribution was causing officer discomfort and complaints.
They needed a new, bespoke solution, fast. The requirements were to ergonomically integrate both new devices, maintain officer comfort for long shifts, and ensure the vests were fully compliant with national standards, all while being durable and cost-effective for a large-scale deployment.
Our UK design team met with the force's procurement and operational units to understand the precise challenges. We took the new devices and, starting from scratch, designed a new load-bearing vest from the ground up.
Using durable CORDURA® fabric, we engineered dedicated pouches and secure, integrated cable-routing channels for both the body-cam and radio. Within 10 days, our in-house UK prototyping workshop delivered the first physical sample for field testing.
During the initial trial, officers provided crucial feedback: one of the shoulder straps was catching on their car's seatbelt. Our agility was key. We re-angled the strap, reinforced the stitching, and had a new, revised prototype back with the client in 48 hours for final approval.
Once the design was signed off, we leveraged our flexible manufacturing capabilities, using our offshore facility to produce the large-volume order, ensuring consistent quality and meeting the client's budget. Every vest underwent rigorous quality control at our UK headquarters before dispatch.
MC Products successfully delivered over 5,000 custom-fit vests on time for the force-wide rollout. The final design provided a comfortable, ergonomic, and stable platform for the new equipment, significantly improving officer comfort and safety. The success of this bespoke project established MC Products as a trusted long-term partner with the force for both manufacturing and future sourcing needs.
