To stop the band from rolling up under the bust, use 5/8-inch strap elastic (which has a plush side and no decorative edge) instead of standard picot elastic. 2. Tailoring & Pattern Adjustments

You can use hooks to strap foam breastplates directly onto a supportive bra to keep the armor from shifting during wear. 4. Quick Fixes: Modesty & Fit

Start with measurements from the shoulder to the bust point, the bust to the underbust, and half the nipple-to-nipple distance.

Use fusible fleece or laminated bra foam for a steady, strong structure. For extra stability, double up on layers of firm powernet for the bra band.

Rather than using a single 6mm piece of foam, layer three 2mm EVA foam sheets together with contact cement. This "sandwich" holds a curved shape much better under the weight of a larger design.