HexPlate Armor

Our Technology

HexPlate Armor blends advanced additive manufacturing, novel materials and bio‑inspired design to create a new class of personal armour. Each hexagonal tile is a self‑contained composite built around a 3D‑printed gyroid lattice, coated with ultra‑hard nanocrystalline Nanovate alloy and filled with a shear‑thickening, non‑Newtonian fluid. A patented tri‑link system joins the plates together, allowing multi‑axis flex while limiting deformation and distributing impact energy across neighbouring plates.

The gyroid lattice — a triply periodic minimal surface — delivers a high strength‑to‑weight ratio and channels the energy of a ballistic impact into controlled, progressive collapse. The Nanovate coating provides exceptional surface hardness and fatigue resistance, while the non‑Newtonian fluid instantly hardens under high shear to suppress spall and further spread the load. The tri‑link connectors terminate in precision‑machined ball ends so that each tile can articulate relative to its neighbours; when struck, the gap between tiles closes just enough to share the force, limiting backface deformation without the need for thick foam layers.

Thanks to additive manufacturing, the plates can be produced in different diameters and thicknesses. High‑flex areas (such as the shoulder, neck or hips) receive smaller, thinner tiles, whereas the chest and back can employ larger, thicker tiles for maximum protection. Combined with a full‑body scan and digital tessellation, HexPlate Armor offers a truly custom‑fit solution tailored to the anatomy and mission of each user.

Key Benefits

• Multi‑hit resilience – Each hex tile acts independently. A damaged tile can be replaced in the field while neighbouring plates continue to function.
• Adaptive energy dispersion – The tri‑link gap architecture and gyroid core convert point impacts into distributed impulses, reducing blunt trauma.
• Lightweight performance – Internal lattices and selective fill keep mass down while achieving rifle‑rated protection.
• Custom fit – Tiles come in multiple sizes and thicknesses. Body scanning and digital tessellation provide a made‑to‑measure armour grid.
• Modularity – Plates snap together via tri‑links; units can upgrade individual tiles as needs evolve without replacing the entire vest.
• Future‑proof – Designed with sensor integration, reactive fluids and smart coatings in mind, ready for next‑generation upgrades.

Development Plan

HexPlate Armor is currently in the prototyping phase. We are refining our additive manufacturing processes, gyroid lattices and modular connectivity to create a reliable, adaptive armour system. As the technology matures we will share updates on our progress.

If you are interested in collaborating, contributing expertise or exploring how this technology could benefit your organisation, please get in touch. Together we can redefine personal protection.

Contact Us

For partnerships, investment enquiries or further information about HexPlate Armor, please email us at info@hexplatearmor.com.