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Of course, the power armors are the best you can get, but generally unless you are really late game, the above loadout will get you far.
a solid flak vest should keep fatalities down. The only weakness of duster/flak vest combo is weaker limb protection. It is very economical and I tend to use it into later game than I should since I am unreasonably put off from making expensive armor due to the fact you can't repair items.
by more expensive armor I meant like... marine and cata. Is the flak armor even worth it? I think dusters/flak vest are actually just better than flak armor.
EDIT: forgot it was flak jacket (not armor)... the wiki has this to say
"With low resource costs, accessible research, and the ability to be worn over flak vests, flak jackets can provide useful protection in the early game. However once sufficient devilstrand is available, typically by mid-late game, devilstrand dusters are almost strictly superior, with their only statistical downside being a tiny decrease in cold insulation. Devilstrand dusters cover the legs, provide slightly more sharp and blunt protection, significantly more heat insulation as well as excellent heat protection, and eliminate the movement speed penalty. "
marine armors for my ranged soldiers
flak vests for my normal colonists
+ all in devilstrand dusters,buttondownshirts and pants if wearable.
Then best armor you can get for the rest of the body. If you can't make flak or marine-type armor, then use broadwrap + mask for the head and devilstrand/thrumbo duster for the body. You can get a flak jacket on top of all that when you find one.
Honestly with all the new genes, I waiting for someone to test how effective a pawn can be with just a tough trait, a skin gland, cata helmet, flak vest, bandolier, minigun and shooting expert. Extreme daka might prove better then armor.
Best armor rating possible: best powered armor you can get(quality and tier), best shirt and pants you can get (Thrumbo>Hyperweave>Devilstrand>anything else w/best quality), best skin hardening you can afford. Further reduce damage with tough trait(luck based) and robust gene(not luck based, but can be tricky to get it).
In depth: Cataphract is the best, even compared against the best layered loadout: all legendary thrumbo button down, pants, duster and flak vest. Just because so many more bullets are deflected by the first layer, other layers won't have to do nearly the same amount of work. Taken damage average for legendary cataphract (~10%) vs duster and vest (~30%). The most important thing is getting an armor piece with the highest rating (armor %) to deflect as many bullets as possible. As long as that number is higher than 145% covering the instakill parts (covers torso, neck, head), you are never going to take full damage, always less than half. 45 AP is the best AP available from charge lances btw, therefore 145% - 45 AP = 100% effective armor for calculation.
Conclusion: two layered pieces of medium armor is less effective than heavy armor.
The caveats:
Move speed cost: armor speed offset is taken before multipliers like movement boosts from limbs, drugs, etc. A jogger can offset up to .4 movement speed, and bionic legs(or 125% movement) can offset cataphract speed. You are still giving up speed, but if they can keep up with your normal colonists, you probably don't care too much.
Manufacture cost: powered armor is expensive to make and 'rare' to buy (only 1-2 per trader), clothing can be easier to get, but the apparel I used for best values is also incredibly hard to get (thrumbos and quality).
Time spent giving a ****: point in case
Flak gear: spend components instead of thrumbofur/hyperweave for similar armor value with the duster and pants. The vest is a unique piece, so get it unless you have powered armors, plate armor is worse than the vest in every way.
Invincible pawn?
With genes, you can pull off some amazing things. Short answer yes: with a cataphract helmet on a tough sanguophage, you will survive 99.99% of encounters. The only way they die is multiple shots to the same critical part (brain, neck, heart, liver), which just isn't going to happen under any circumstances, since the most lethal shots only do about 6 damage after making it through the helmet.