Combat armor maybe instead of metal armor?
Combat armor at least comes in regular and heavy variants, with heavy having much more plating visible. haven't seen mark 2 metal armor yet but there is a precedent for it in fallout.
I found synth amour that has a lower and upper arm section to it looks like a kind of arm brace, ironically less defence than the leather piece that only has forearm.
This seems to be the pattern with most Synth equipment. Remember- Institution weapons deal significantly less damage than their laser counterparts.
Yeah i noticed this but it didn't come with any sort of great advantage over any other stat so say lower damage but faster fire rate or better reload speed!!
As beng said, there are multiple tiers for each armor. Normal, sturdy and heavy, each tier adds additional parts to the armor.