YOCC - Bio-inspired Design of Human Armor

What it does

This is a modular series of multifunctional sports protectors—including helmets, knee pads, elbow pads, and wrist guards—utilizing a unique combination of hexagonal units and interlocking structures to disperse shock.

Your inspiration

It draws inspiration from the interlocking wing cases of beetles, which exhibit outstanding impact resistance and mechanical stability in nature. Studying these biological defense mechanisms, we found that beetles efficiently dissipate force through these natural joints while maintaining lightness and flexibility. In contrast, most commercial protective gear is bulky, uncomfortable, and lacks intelligent features. Our goal was to combine nature-inspired mechanics with flexible sensing to create a wearable solution offering both superior protection and smart feedback.

How it works

Its exoskeleton is made of interlocking hexagonal structures manufactured via 3D printing and thermal bending. These units stay structurally stable during impact and dissipate energy through friction between elements. A shock-absorbing foam layer inside reduces impact forces, while embedded flexible electronic fibers record pressure data. Users can view real-time feedback through a mobile or desktop app to better understand impact points and improve training posture.

Design process

We started by analyzing various natural structures, eventually selecting the beetle's interlocking hexagonal wing case as our structural prototype. Through multiple rounds of digital modeling, 3D-printed prototyping, and mechanical testing, we finalized the optimal configuration and thickness. The foam layer was tested across different materials for the best support-comfort balance, and flexible conductive fibers with stable signals and high anti-interference were selected for the sensing layer. The final design adapts ergonomically to different body parts.

How it is different

It breaks the boundaries of conventional rigid protection by merging biomimetic structures with soft electronics, achieving a balance of lightweight design, smart feedback, and superior impact performance. Tests show YOAA improves shock resistance by over 49% compared to non-interlocking hexagonal counterparts.

Future plans

We aim to extend the YOCC series to children’s sports, elderly rehabilitation, extreme sports, and military training, while enhancing the companion software for more precise analysis and personalized training advice. The interlocking hex structure also holds promise in fields such as robotic exoskeletons and seismic-resilient architecture.

Awards

YOCC was awarded the Gold Medal in the Protective Products category at the 50th Geneva International Exhibition of Inventions.