CASE STUDIES

OPSGEAR Vest Builder

2011

OPSGEAR Vest Builder

Role

Lead UX / research / development

Role

UX / research / development

Timeline

8 months

Timeline

8 months

Platform

Desktop / web

Platform

Desktop / web

Platform

Desktop / web

Impact

Jump in sales

Impact

Jump in sales

Impact

Jump in sales

OPSGEAR was a small Utah-based retail company that served the military, law enforcement, and military-simulation recreation communities. Whatever the mission, duty, or game session, one thing in common across all of these diverse groups is the need to wear a duty vest that can hold a staggering variety of gear, from medical kits to weapon or ammunition pouches to radio, command, or navigation devices.

Vests can be purchased pre-configured for a particular type of duty or operation, but most prefer a modular approach, where the base vest is outfitted top to bottom only with a series of narrow straps upon which the user then adds a number of purpose-specific pouches that weave onto the straps.

PROBLEM

Although OPSGEAR stocked thousands of pouches for every conceivable purpose and in every conceivable duty color, we weren't seeing the sales and adoption specific to vests and customizations that would be expected considering the steady sales in other product lines for the same markets. There seemed to be a blind spot in product awareness.

A companion theory was that to those who were experienced in purchasing and configuring a vest in person, browsing an online store isn't ideal when you can't see how the pouches of various sizes will fit together when space is limited.

The solution: the Vest Builder

OPSGEAR vest builder launch screen
OPSGEAR vest builder launch screen

The OPSGEAR main launch page

The Vest Builder was to be an interactive application that would allow the user to select a vest style and color, then add pouches and rearrange by dragging them around on screen to the exact position and fit for their needs. The main goal was to build confidence in the purchase and drive sales.

RESEARCH AND DEVELOPMENT

The target user bases for the Vest Builder aligned neatly with the three major market segments for OPSGEAR as a whole. Understanding each market required an understanding of their core goals and needs, and so we started by documenting the main needs of the three personas:

Military User

  • May be assigned to multiple operations over career, will have different needs for each

  • Will need optimal vest configuration for each assignment or theater

  • Builder values: speed and variety of product selection

Law Enforcement User

  • May only make one or two long-term vest purchases over career

  • Needs are less likely to vary over time, so purchases are carefully considered

  • Vests may be fully dictated by department in configuration or color

  • Builder values: accuracy and product interoperability

Milsim (Military Simulation) User

  • Recreational users, inspired by military in popular culture to go to remote areas in groups and play competitive war games (e.g. airsoft or paintball)

  • More likely to make multiple purchases, different colors and configurations

  • Values playability from builder, ability to quickly see different colors / configurations and share and compare with teammates

Being in such a small company where everyone wore many hats, I was responsible for the entire implementation of the app (including product photography) with the exception of the initial UI concepts. The app was built in Adobe Flash using a simple XML file as the data store, and a separate admin app to make it so anyone could add or remove pouches.

GUERILLA TESTING

Strangely enough, much of the testing for the Vest Builder happened at unexpected times during development. The CEO of OPSGEAR was himself ex-military, and the retail store attracted many friends of his across military and law enforcement. He would often grab whoever was in the store at the time (maybe a Salt Lake City police officer, or an ex-Air Force Security Forces member) and bring them up to the media office to have them check out this new application we were working on.

The at-first unprompted feedback gave us some unexpected and extremely valuable insight into the needs of our target audience. After the first couple of surprise drop-ins, I insisted that anyone else in the store with a military or police background come up immediately to sit and try to configure a vest.

INSIGHTS AND ITERATION

Some of the most insightful feedback included comments like:

"My department regulations say we can only wear black."

– Salt Lake City SWAT Officer

"I'm a field medic, how do I find the first aid and trauma kit pouches?"

– Utah National Guard Member

Which led directly to the addition of new features including:

  • Filtering vests and pouches by color

  • Filtering pouches by type

  • Creating pre-configured options when called for by organization

  • The ability to email yourself a list of all of your configured items with shopping links to purchase late

To further drive sales and meet business needs, we then worked closely with our e-commerce provider to develop a custom process to allow us to add an add-to-cart button, linking directly to the online store's shopping cart, with the user's chosen vest and pouches already added and ready for purchase, reducing friction even further.

FINAL DESIGN

Most of our team's journeys begin at the whiteboard. Over several days I mapped and re-mapped the architecture of the app, soliciting feedback and testing with people from across the company to help solidify the app's user journeys.

I put several sketches on paper or in Sketch to address the key insights head on. We wanted to put the members' account balance information immediately in view on opening the app, and then show the members a menu of quick actions to accomplish the other high-frequency tasks.

OPSGEAR vest builder main interface large
OPSGEAR vest builder main interface large

The main Vest Builder interface with filtering at the upper right, and a thumbnail list at the right

LESSONS LEARNED

As one of my first experiences designing and iterating on a user-focused product, some of my biggest early UX lessons were born from the process. Among the biggest are:

As one of my first experiences designing and iterating on a user-focused product, some of my biggest early UX lessons were born from the process. Among the biggest are:

"I am not my target audience"

– UX axiom

Given my complete lack of military or law enforcement experience, I relied heavily on those early testers who gave candid, and sometimes blunt but necessary feedback that helped make a better product.

"No plan survives first contact with the enemy"

– Prussian Field Marshal Helmuth von Moltke the Elder

See also:

"Everybody has a plan until they get punched in the mouth"

– Mike Tyson (paraphrased)

Your best ideas and strongest designs won't succeed if not tested and validated with actual users. Be prepared to pivot fast when new or insightful feedback comes in.

This early work reinforced the value of continuous discovery and frequent testing. The feedback from this fast-fail approach helped solve usability issues and add valuable features before launch, and the Vest Builder quickly became one of our most popular products across our commerce and media operations.

Copyright © 2026 Kevin Jackson.

Copyright © 2026 Kevin Jackson.