Protective Fencing Gorget

Design Considerations

Lightweight construction
Resistance to repeated impacts
Ease of manufacturing
Unrestricted range of motion
Effective blade deflection
Compatibility with existing masks

Design Solution

I developed an add-on protective system that could be integrated with an existing fencing mask, avoiding the cost and complexity of manufacturing an entirely new helmet. The design focuses on creating a continuous surface that encourages incoming blades to glance away rather than catch along the lower edge of the mask.

A key design decision was to separate protection from flexibility. Rather than relying on movable or segmented armor, I used a rigid, 3D-printed PLA (polylactic acid) shell to provide the intended deflection geometry, while a flexible fabric backing accommodates differences in fit and movement. This approach allowed me to prioritize a consistent protective shape without making the entire assembly rigid.

My initial approach was to redesign the fencing helmet itself, modifying its profile to reduce the likelihood of upward-angled strikes catching along the lower edge.

Although this approach offered a potential solution, the cost of manufacturing an entirely new helmet made it less practical than developing an attachment compatible with existing equipment.

Initial Concept

Second Concept: Segmented Gorget

I next explored a segmented gorget inspired by historical articulated armor, including lorica segmentata. The overlapping segments offered greater flexibility and adjustability, potentially accommodating different users more effectively.

However, during evaluation, the segmented configuration did not consistently redirect incoming strikes. The gaps and movement inherent in the design presented challenges for maintaining a reliable deflection surface, leading me to reconsider the protective geometry.

Final Concept: Rigid Shell and Flexible Backing

For the third iteration, I replaced the segmented configuration with a continuous, rigid 3D-printed shell. The objective was to create a consistent deflection surface while keeping the assembly relatively lightweight and straightforward to manufacture.

I also refined the shell's geometry to increase neck clearance, allowing greater freedom of movement when worn with the fencing mask. The protective component was then attached to a flexible backing that could conform to the wearer.

Prototype Testing and Next Steps

I evaluated the completed prototype through HEMA sparring and controlled sword strikes. During initial testing, the 3D-printed shell resisted visible damage and redirected incoming blades, while the flexible backing also remained intact.

However, the stitching securing the assembly failed, revealing a weakness in the attachment method. The installation also required extensive sewing, making it difficult for users without experience to attach the gorget correctly.

For the next iteration, I plan to investigate stronger stitching materials and alternative attachment methods, including options that eliminate sewing altogether. The goal is to improve installation, attachment reliability, and accessibility without sacrificing the intended protective geometry.