The Outer Tactical Vest (OTV) is a modular soft armor system; its protection can be tailored to a particular mission threat by adding or removing subcomponents. The OTV provides fragmentation and 9mm bullet protection and replaces the Personal Armor System - Ground Troops (PASGT) vest currently fielded. The OTV base vest weighs less than 6.5-lbs. It provides the wearer with improved fragmentation protection plus 9mm bullet protection at a weight savings of about 18% over the PASGT vest it replaces. A removable collar, throat protector, and/or groin protector may be affixed to the vest to increase its area of protection and casualty reduction potential. The exterior of the vest is covered with MOLLE-compatible webbing hangars that accommodate load carriage using a variety of standard pouches and pockets. The vest is also designed to be compatible with the FLC, ALICE, MOLLE and ILBE load carriage systems. Currently produced in solid shade Coyote brown only, a single OTV may be worn with the Corps' MARPAT camouflage in both desert and woodland environments. OTV is available in five sizes, XS through XL, with the same sizing system used for the SAPI plates.
Small Arms Protective Insert (SAPI) plates provide additional protection for vital organs. Pockets integrated into the front and rear of the vest securely hold one or two plates. When SAPI plates are not worn, the front SAPI pocket retracts into the shell for reduced overlap and passive cooling. The rear pocket is fitted with a hole, which permits it to be used for carrying an on-the-move hydration system bladder within the vest. The OTV shell and ballistics are separate sub-components, permitting replacement for repair or upgrade without obsolescing the entire system. The Interceptor body armor jacket could stop 9mm handgun bullets in their tracks. Siliconized silicon carbide and boron carbide plates that can stop rifle or machine-gun fire - which was not possible with this jacket in the past - are now available to insert in the jacket's pockets. Simula, with a production capacity of 5,000 plates per month, had delivered 45,000 of its siliconized silicon carbide plates by 2002 and at that time was under contract to deliver 140,000 more; 12,000 of CERCOM's boron carbide plates had also been fielded by 2002. The new armor plates were 55% lighter than traditional body armor, and had a cost approximately 60% lower than the high performance armor plates that were available at the start of the.