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Introduction Carrying heavy loads and body armour may alter posture and increase the risk of low back pain in military personnel. This observational study aimed to assess how two designs of body armour affect posture and pain in German soldiers following loaded marches.Methods In this prospective observational study, 20 soldiers (male healthy volunteers) completed three 12-km marches under three conditions: without body armour (control), with old-design armour and with new-design armour featuring a hip belt. Spinal posture (forward trunk lean as primary outcome) and pain were assessed using video rasterstereography and visual analogue scales before and after each march.Results Significant differences in forward trunk lean were observed with new-design armour compared with control (mean difference 6.1 mm, p=0.006) and old-design armour (mean difference 5.4 mm, p=0.046). Pain increased significantly after marching with old-design armour (lumbar pain: p<0.01; thoracic pain: p=0.01), but not with the new-design armour.Conclusion Body armour design notably affects spinal posture and pain. Although the new design increased forward trunk lean, it did not significantly increase pain, suggesting potential ergonomic advantages.