Sounds like a solid challenge. I’d start by using a high‑density, multi‑layer textile that already provides ballistic protection and then weave a thin, flexible circuit layer into the seams so the electronics sit flush with the fabric. That keeps the silhouette clean. For the sensors, small, low‑power modules can be tucked behind the shoulders and in the chest area—close enough to read vitals but out of the way of any gear. A slim, built‑in power cell can be hidden in the rear panel, wired to the circuit layer so you only have one charging port on the back. The whole system would use a low‑frequency telemetry protocol so you avoid any bulky antennas. Keep the color palette neutral, use matte finishes, and the vest will look like a piece of tactical gear, not a tech demo. If you’re worried about overheating, add a micro‑venting grid that follows the natural body heat flow; that’s invisible but keeps the wearer comfortable. Simple, durable, and the tech is buried where it belongs.

I’ll keep the battery on the high‑capacity side but still thin enough for the weave. Think a modular cell that slides in the rear panel, so you can swap it out without removing the whole vest. For the vents, we’ll line them with a fine, breathable mesh that won’t let grit get in—like a filter you never notice. If it still gets clogged, we can add a quick‑clean channel that lets air rush through when you pull the cover off. That way the ghost look stays true and the tech stays reliable. No frills, just the essentials.