Bras, Body Armor, and a Surprising Ph.D. Journey
When Andrea Porter took a break from her job to earn a Ph.D. in multidisciplinary engineering, she didn’t expect to become a bra fitting expert—or to be testing body armor on a shooting range. But her research into how well armor fits and protects women took her on that exact journey.
How It Started
While living in Texas, Porter mentored high school girls—some of whom later joined the military or law enforcement. They told her how uncomfortable and even painful their body armor was. Porter was surprised—she had assumed armor was already designed with women in mind.
One example: a soldier said her armor’s long shape pushed her helmet down when she lay on the ground, blocking her vision. A police officer showed scars from armor rubbing her chin during patrols. Running was difficult, too—women had to either hold their vests or tighten them so much it was hard to breathe.
Porter realized she might not be on the front lines, but she could help by improving the gear these women depend on.
The Bra Connection
Porter has always been interested in ergonomics—the science of designing tools and environments to better fit people. Her research advisor, Dr. Mark Benden at Texas A&M, encouraged her to study women’s armor more closely. What she found was surprising: a woman’s bra affects how her armor fits.
In a survey of nearly 1,000 female officers, many said their bra type made a big difference in comfort and movement. Some even said not wearing a bra was more comfortable under armor.
"Armor fit isn’t just about size—it’s about how the gear interacts with the body and what’s underneath," Porter said.
She also found that many armor fitters are men, which makes conversations about bras and fit awkward. So she’s working on guides to help both male fitters and female officers talk more openly and professionally about these issues.
Testing on the Range
Porter didn’t expect her research to take her to a shooting range, but that’s where she tested how well armor protects against bullets when it doesn’t lie flat against the body—like over the breasts.
With help from Survival Armor, a company run by women, she tested vests on a dummy with silicone breasts, bras, and soft armor. She found something surprising: gaps between the armor and the body actually reduced injury from bullets.
Current armor tests assume the vest lies flat on a clay block, but real people—especially women—have curves. Porter’s research shows those differences matter.
Making a Difference
Law enforcement agencies across the U.S. are now paying attention to her work. Porter wants to help female officers get better-fitting, more protective gear. She also wants to break the taboo around talking about bras in a serious, respectful way.
At one point, she considered dropping the bra topic altogether because it felt uncomfortable and was often joked about. But her advisor reminded her that science isn’t always easy or comfortable—it’s about discovering the truth and helping people.
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