The Belfast-based start-up Vikela is transforming the body armor industry using 3D printing technology to deliver customizable, lightweight, and highly adaptable protection solutions.
From Concept to Innovation
Founded by Peter Gilleece, Vikela—meaning “to protect” in Zulu—was created with the goal of producing body armor that is more comfortable, flexible, and better fitting than traditional gear. While 3D printing was not the original plan, it quickly became the optimal solution for achieving this vision.
The Limitations of Traditional Armor
Conventional body armor, though effective, often comes with significant drawbacks: it restricts mobility, contributes to fatigue, and typically does not offer sizing diversity, particularly for women. As a result, wearers may be disincentivized from using it consistently—putting lives at risk.
Rethinking Materials and Manufacturing
Instead of modifying current materials like Kevlar, Vikela reengineered the entire design and production process. The company developed a unique polymer powder, used with Selective Laser Sintering (SLS), to produce armor that mimics natural protective systems—like the layered structure of a snail shell.
The armor’s interlocking hexagonal structure resembles chainmail, allowing it to flex in multiple directions and improve wearer comfort. Vikela’s approach also enables the same material to be printed with properties tailored for either soft or ballistic-level protection, based on how the layers are structured during printing.
Advanced Process, Tailored Fit
The SLS printing method includes a proprietary in-process treatment step that enhances layer adhesion and strength. This means that armor pieces are printed in a single step—no additional assembly required—and can be customized for any body size or carrier system.
This flexibility enables Vikela to serve both individual customers and organizations looking to upgrade existing gear without replacing entire systems. The armor can be integrated seamlessly into current carrier systems, including those with mounts for body cams or other accessories.
Modular Protection Levels
Vikela offers three levels of protection that can be added or removed based on threat assessment—ranging from stab and spike resistance to rifle-grade ballistic protection. This modularity allows wearers to remain protected without carrying unnecessary weight.
Safety and Certification
Currently certified in the UK for knife and spike protection, Vikela is pursuing international certifications such as those from the National Institute of Justice (NIJ) in the U.S. and VPAM in Germany. Internal tests have demonstrated ballistic effectiveness, though certification processes are complex for such a novel product.
Despite being a few millimeters thicker than traditional armor, Vikela’s superior fit offsets any additional bulk. Its multi-directional flexibility makes it notably more comfortable and less visually intrusive under clothing.
A Market on the Rise
With increasing demand for personal protection, Vikela sees growing interest from private security, emergency responders, and public-facing professionals. Their discreet, form-fitting armor offers safety without compromising mobility or appearance—critical factors in adoption.
Named among the UK’s top 100 start-ups of 2025, Vikela represents a new era of protective wear—driven by design, enhanced by technology, and focused on real-world usability.
