04 / HUMAN FIRST / NON-WEAPON MEASURES

PROTECT THE PERSON.
NOT THE FANTASY.

“Defensive measures” here means reducing the suit’s own hazards and helping the wearer stay aware. No weapons, injury-oriented deterrents, or claims of combat protection.

01 / PASSIVE MEASURES FIRST

A safer costume is an engineered system.

Mechanical escape

Independent face, hand, and body releases. Opposite-hand operation. No spring-pin release or dependence on software to free the wearer.

Pinch & edge control

Guarded joints, smooth edges, protected moving clearances, and no rigid material forced into joint folds. Padding is not a repair for bad alignment.

Heat management

Ventilation routes, cleanable air paths, local temperature advisories, and a straightforward way to stop and remove the suit.

Visibility & awareness

Direct sight lines, gentle marker lights, reflectors, open-ear communication, and optional advisory rear/side sensing.

Electrical isolation

Insulated harnesses, appropriate source/branch protection, accessible disconnects, and protected battery retention. No chassis-as-return shortcut.

Stable support

A retained dressing stand and deliberately controlled load paths. No automatic locking of knees or hips in response to a software fall guess.

Context: NIOSH · Exoskeletons in construction NIOSH · Heat stress

Metal skin is not protective certification. This project has no ballistic, fire, respiratory, fall-arrest, electrical-PPE, or certified impact rating. It must not be used as a substitute for appropriate protective equipment.

02 / FAILURE BEHAVIOR / INTERFACE MODEL

What happens when something stops?

This interactive table illustrates the proposed separation of control domains. It is not firmware, a wiring test, or a hardware safety demonstration.

LIGHT ACCESSORY MOTIONLOCALLY ENABLED

COMFORT / LOCAL ALERTSPOWERED

MANUAL RELEASESMUST REMAIN ACCESSIBLE

Proposed operating state only. Load-bearing joint motors are not part of D01. Manual mechanisms are not yet validated.

Total disconnect removes electrical cooling. An accessory motion stop does not unload springs, hold a falling component, or release a non-backdrivable gearbox.

03 / THE TEST GATES

Earn the next stage.

Gate	Required evidence	Current status
Fit & comfort	Personal measurements, movement baseline, padding/contact checks, and adjustable unloaded mockups.	Measurements incomplete
Independent access	Full opening paths, latch approach with gloves, release forces, supported entry, and off-stand removal.	Opening conflicts recorded
Mechanics	Constrained joint design, retained hardware, spring behavior, continuous load path, independent review.	Incomplete
Manufacturing	Known alloy, casting trials, machining plan, inspection, static and fatigue testing off-body.	Not performed
Electrical bench	Protection coordination, connector checks, cable movement, thermal faults, loss-of-power behavior.	Draft architecture only
Human trials	Prior review, low-load controlled testing, a spotter, stop criteria, and demonstrated exit.	Not authorized by these files

Independent final use is the goal. Early loaded development testing is not a solo activity.

PROTECT THE PERSON.NOT THE FANTASY.

A DEAD BATTERYMUST NOTKEEP YOU INSIDE.