Technical Plate Carrier Review: U.S. Army IOTV Issued Plate Carrier

The Improved Outer Tactical Vest (IOTV), introduced by the U.S. military in 2007, marks a notable improvement in body armor technology. It provides enhanced protection and modularity for soldiers in combat. Initially deployed during the Iraq and Afghanistan conflicts, the IOTV replaced the older Outer Tactical Vest (OTV). Key features of the IOTV include better weight distribution, an emergency quick-release system, and improved ballistic protection. Despite the adoption of newer systems like the Modular Scalable Vest (MSV) starting in 2018, the IOTV continues to be used by various U.S. military units and allied forces, highlighting its durability and widespread use. This review will examine the latest generation of the IOTV, the Gen 4.

Over its decade-plus service, the IOTV has been criticized for its weight, particularly by dismounted infantry. Meanwhile, the commercial market has trended towards lighter, more minimalist plate carriers. For many military personnel, the IOTV is their primary experience with body armor. This raises important questions: do scalable systems like the IOTV remain relevant today, and how do they compare to the latest commercial innovations? Read on or watch below this installment of Qore Performance INSIGHTS to find out.

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Format

For newcomers to this series, our technical overviews aren’t standard “reviews.” We developed them to answer frequent customer questions about integrating our IceAge Ecosystem’s thermoregulation and hydration tools with various plate carriers available today. Our approach is strictly empirical: we present objective, quantifiable data supported by instruments and documentation whenever possible. We strive to avoid any subjective or qualitative information. We don’t share conjecture or opinions. We aim to provide the data necessary to make informed decisions, empowering you to reach your highest potential. That is what Building A Superhuman Future is all about.

IceAge Ecosystem Integration

Thermoregulation is the next night vision. Since our inception, we’ve asserted that eliminating temperature constraints in combat can be as transformative as operating in complete darkness. Thus, our IceAge Ecosystem of thermoregulation and hydration tools is central to this INSIGHTS series.

Despite its age, the IOTV is fully compatible with our IceAge Ecosystem and is designed, in part, to modernize older plate carriers. Our system’s cooling, heating, and hydration core, the ICEPLATE® Curve, can be mounted internally via the IMS Versa for conductive cooling and heating and to provide 50 fl oz (1.5 L) of hydration. Additionally, the IMS can be attached externally on the rear plate bag for hydration or in tandem with the IMS Versa Combo for a combined total of 100 fl oz (3 L) of hydration. One member of the IMS family that is not compatible is the IMS Pro. This is due to the IOTV lacking an internal loop Velcro or MOLLE field.

CATAMARAN effectively creates ventilation between the plate bags and your body for convective cooling using ICEVENTS® Classic Ventilation Pontoons. ICEVENTS® Aero and ICEVENTS® Classic shoulder pads also seamlessly integrate with the IOTV.


For turn-key solutions to upgrading your plate carrier, check out our Plate Carrier Upgrade Kit.

 

IceAge Ecosystem Integration Comparison Chart

Weight

Dry Weight

Weight significantly affects human performance—every ounce adds up, and every pound matters. This is a well-known fact, particularly among those using body armor systems like the IOTV. One of the most common complaints about the IOTV system is its weight. Given that the IOTV is a modular, scalable system, we’ll measure two configurations: one for the plate carrier alone and another with the additional collar, deltoid, back, and groin protection add-ons. Note that these weights do not include the soft or hard armor.

Dry, with just the front and rear plate bags and cummerbund, the IOTV weighs 58.4 ounces (3.65 pounds).

When fully equipped with all protective add-ons, the IOTV weighs 131.2 ounces (8.2 pounds). To see how this compares to other carriers like our ICEPLATE EXO® Gen 3, Crye Precision JPC 2.0, Crye Precision AVS, or Shaw Concepts ARC V3, check out our Best Plate Carriers 2024 article and video. We’ve compiled one of the most comprehensive databases of plate carrier data available to ensure you have all the information needed to make an informed decision.

Wet Weight

Does wet weight matter more than dry weight? It depends on your mission. Whether dealing with salt water or sweat, a plate carrier’s ability to repel and shed water weight quickly can significantly affect operator performance. When wet, the IOTV with just the plate bags and cummerbund weighs 82.4 ounces (5.15 pounds). With all protective add-ons, it comes to 171.2 ounces (10.7 pounds).

For those who have seen our Technical Plate Carrier Overview series, you know our testing method is straightforward and consistent across all plate carriers:

• Submerge the carrier in water for 60 minutes.

• Hang it to dry for 60 seconds.

• Record the weight.
  
  
  

All tests are conducted in our controlled HQ2 facility in Knoxville, TN, to eliminate external variables like sunlight and wind.

Thermal Transmittance

What is Thermal Transmittance, and why does it matter for plate carriers?

Thermal transmittance is the rate at which heat passes through a material. For plate carriers, it relates to the body-facing side of the plate carrier plate bag. Well-insulated materials, such as walls or Winter jackets, have low thermal transmittance and effectively protect against external temperature changes, making them suitable for environments like homes, vehicles, or cold-weather gear. In contrast, materials with high thermal transmittance are advantageous for active gear, like running clothes, P.T. outfits, combat uniforms, or plate carriers, as they allow the body to release excess heat generated during physical activity.

Tactical gear inherently provides some insulation, so selecting equipment, especially plate carriers and body armor, with high thermal transmittance is crucial. This allows your body’s natural cooling processes to function efficiently, helping you manage body temperature independently of your gear. This is essential for preventing heat-related issues and maintaining effectiveness in the field. Some plate carriers, like our ICEPLATE EXO® Gen 3, enhance your body's thermoregulation, boosting performance. For those lacking this feature, integrating items from our IceAge Ecosystem, such as the IMS Pro, IMS Versa, ICEVENTS®, and CATAMARAN, can improve thermal efficiency, comfort, and performance.

For a detailed understanding of heat transfer methods and their relevance to your gear, check out the infographics in our INSIGHTS blog article “The Methods of Heat Transfer,” linked in the show notes below.

For those interested in the specifics of our Thermal Transmittance testing methodology, here is our experimental design:

1. Take a FLIR camera surface reading of the body-facing side of the plate bags at room temperature.

2. Place a single ICEPLATE® Curve, fresh from the freezer, into the plate bag.

3. Close the plate bag and place a hard armor plate on top for 30 seconds to simulate wearing the plate carrier. This short exposure tests efficiency, not capacity.

4. Remove the hard armor plate from the surface.

5. Take a new FLIR surface temperature reading.

Interpreting these numbers is straightforward: the smaller the difference between the initial surface temperature and the room temperature reading, the lower the thermal transmittance of that plate bag. This means the carrier traps and retains more heat, making you hotter. Conversely, a larger difference indicates higher thermal transmittance, allowing the plate carrier to dissipate heat more effectively and letting your body’s thermoregulation mechanisms function more naturally.

The IOTV’s baseline surface temperature is 84.1°F, and the ICEPLATE® inside surface temperature averages 63.8°F, resulting in a Thermal Shift of 20.3°F.

The table below shows how the IOTV compares to other plate carriers tested: [data table on screen]

Despite its bulkier design, the IOTV performed well in this test due to the thin material used for the plate bags' body-facing side, allowing for efficient heat transfer. This performance would vary with the included soft armor panels, adding more material through which heat needs to escape, so we decided to include that testing also.

With the soft armor panels inserted, the IOTV’s baseline surface temperature is 83.55°F. With the frozen ICEPLATE® inside, the surface temperature came in at 82.88°F. This gives us a thermal shift of 0.75°F, a completely different outcome compared to the test without the soft armor. This additional test was crucial because the IOTV can be configured from a plate carrier setup with hard, rifle-rated plates for ballistic threats to a comprehensive body armor system with both soft and hard armor, designed to protect against bullets, frag, and shrapnel.

Depending on your operational needs, the inclusion of soft armor may be necessary. However, it's important to note that it significantly affects thermal transmittance.

The tables below represent the thermal shift data from the plate carriers we featured in Best Plate Carriers 2025:

These tables show how the Best Pate Carriers of 2025 contestants stack up against the entirety of other plate carriers we've tested in our technical review series: 

 
Below is a comparison of plate carrier's Thermal Shift that we have tested. Let’s talk about what Thermal Transmittance actually is and why it matters.

Learn more about Methods of Heat Transfer here.

Attachment Mechanisms

The IOTV allows for Velcro, MOLLE, and SwiftClip compatibility. The IOTV does not have zipper back panel capability.

Variety

The IOTV was made originally in UCP camouflage, with later generations made in the MultiCam-like Operational Camouflage Pattern (OCP), also known as Scorpion W2.

Country of Origin

Country of origin is a critical consideration when selecting a plate carrier. COO is a dependable but not absolute indicator of innovation, quality, and craftsmanship. The IOTV is manufactured in the United States by various defense contractors such as BAE Systems and Point Blank Enterprises, ensuring compliance with U.S. regulations like the Berry Amendment, which mandates domestic production for military body armor.

Country of Origin Comparison Chart

Sizing Adjustability

The IOTV is available in various sizes to fit different body types and ensure proper protection. The available sizes include:

Standard Sizes:

1. Extra Small (X.S.)

2. Small (S)

3. Medium (M)

4. Large (L)

5. Extra Large (XL)

Extended Sizes:

1. Medium-Long (ML)

2. Large-Long (L.L.)

3. Extra Large-Long (XLL)

4. 2X Large (XXL)

5. 3X Large (3XL)

6. 4X Large (4XL)

The shoulder straps have 8.25 inches of adjustability, and the cummerbund has 4.37 inches of adjustability.

Price

Price is the least important factor when choosing a plate carrier, as it concerns life-saving equipment. The IOTV Gen 4 we are reviewing can be found on the surplus market for approximately $1,200 to $1,500, including Deltoid Protector Assemblies and a Groin Protector. Prices can vary based on condition, and purchasing just the plate bags and cummerbund can cost between $500 and $800. This makes the IOTV the most expensive plate carrier we have reviewed in our INSIGHTS series thus far.

Conclusion

That concludes our technical overview of the IOTV. In contexts such as near-peer conflicts involving artillery, like the War in Ukraine, the modular protection the IOTV offers can be invaluable. For others, the added weight and bulk might impact performance and survival. Your specific use case will determine which equipment best suits your needs.

We hope you found this overview both informative and enjoyable. Have you been issued an IOTV, or are you currently using one? We’d love to hear about your experiences. Share your stories and insights in the comments below!

To stay updated on the latest in All-Aspect Thermoregulation and more, follow us on Instagram at @qoreperformance and subscribe to our LaunchPad email list. Join us in Building A Superhuman Future®.

Until next time, #StayFrosty!

About Qore Performance

For those of you who are new to Qore Performance, we live for Building A Superhuman Future. It is why we exist. We help customers be the greatest version of themselves, to create competitive advantages where none previously existed. We design, build, and manufacture thermoregulation and hydration solutions that weaponize temperature to improve performance and survivability for military, law enforcement, prepared citizens, pilots, outdoor enthusiasts, and industrial professionals at America’s greatest companies. If you’ve purchased chicken or coffee from a drive thru in the United States, there is a high probability you’ve seen our ICEVEST HiVis Safety Vests, our ICECASE iPad Cooling cases or both in use while rolling through one of these corporate powerhouses.

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