Imagine a firefighter inside a burning building. Their protective suit shields them from heat so effectively that they can no longer feel the danger – and that may prove fatal, writes Paula Veske-Lepp, Visiting Professor at the Institute of Technology and Circular Economy at TTK University of Applied Sciences.
Modern protective clothing is such an effective thermal insulator that its thick layers can mask the sensation of heat. The body’s natural warning mechanism – the instinct to retreat from danger – may reach the brain too late. By the time a firefighter feels the heat, burns may already have occurred. This is one of the paradoxes of modern protective clothing: the properties that protect people can also conceal danger.
A sensor that replaces the sensation of pain
One possible solution is to integrate temperature sensors into protective clothing to warn the wearer before a critical threshold is reached. Such a garment continuously measures heat flow between the outer and inner layers and provides an audible warning when the heat load requires action. In this way, the sensor provides information that the wearer’s natural perception of heat can no longer deliver through the thick insulating layers.
It is important to emphasise that the sensor does not make decisions for the wearer. It provides timely information that allows the person to assess the situation and decide how to act. Several research consortia in Europe have explored such solutions. One example is the I-CART project developed in Belgium, which originated from the Paris Fire Brigade’s need to reduce burn injuries caused by heat exposure.
The project’s distinctive feature was its focus on a single parameter – temperature – in order to create a solution that was as reliable and practical as possible. This demonstrates that the value of effective smart textiles does not lie in collecting as much data as possible, but in delivering the most important information to the user at the right time.
The greatest technical challenge is no longer developing sensors themselves, but ensuring their reliability. Components must withstand high temperatures, moisture and mechanical stress without creating additional risks for the wearer.
Solutions must also function under real-world conditions: conductive textiles and flexible electronics need to withstand repeated bending and washing; sensors must continue to operate when the fabric is stretched or creased; and the entire system should function with as little energy consumption as possible.
Smart textiles are born through collaboration
Developing such solutions requires knowledge from very different fields. Neither textile technology nor electronic engineering alone is sufficient – both are needed. Equally important is involving end users: doctors, firefighters, athletes and others can help developers understand which solutions actually work in real-life situations.
In practice, this means that finding a common language is often easier through prototypes and visualisations than through specialist terminology. A physical model or drawing can help people from different backgrounds understand an idea in the same way.
The development of smart textiles also raises ethical questions. Because these garments come into direct contact with the human body and are used in everyday life and work, users need to be involved from the very beginning of the development process, rather than only during final testing. What data is collected, who has access to it and how it is used – these are not merely technical questions, but societal ones as well.
More than protective clothing
The potential of smart textiles extends far beyond emergency services. Similar technologies are already being used or developed for applications such as garments containing electrodes for muscle stimulation, automatic detection of falls among construction workers, monitoring the physiological parameters of military personnel, and measuring muscle load and body posture in athletes.
All these solutions share one principle: the textile itself acts as a sensor, without requiring the person to wear a separate measuring device.
This development is directly relevant to Estonia, as Estonian companies manufacture workwear and protective clothing for numerous international markets. The spread of smart textiles means that a new field of expertise is emerging alongside traditional clothing manufacturing, increasingly bringing together the textile industry, sensor technology, electronics, data analysis and software development.
At the same time, adding technology to a garment does not automatically make it a better or more sustainable product. Smart components make garments more complex, more expensive and often more difficult to recycle. That is why considerations about durability, repairability and end-of-life disassembly need to be incorporated from the very beginning of the development process.A well-designed smart garment could be one answer to the challenge of combining safety, greater added value and more sustainable production.
In spring 2027, Tallinn will host the European Conference on Protective Clothing (ECPC2027), bringing together researchers, manufacturers and emergency services from around the world. The conference will address, among other topics, smart textiles, protective clothing safety and sustainable solutions.
* Article was published on July 31, 2026 in Novaator.
