AeroFlex® Turnouts
REVOLUTIONIZING FIREFIGHTER SAFETY
AeroFlex® revolutionizes firefighter safety with unmatched breathability and heat stress protection. Designed with VaporLite® Panels and AeroVent® Technology, AeroFlex® supports core body temperature regulation, encouraging airflow to keep your body cool and comfortable without compromising the protection you need!
A RISING EPIDEMIC
| 65% | Overexertion/Stress | |
| 11% | Crashes | |
| 11% | Caught, Trapped | |
| 8% | Struck-By Incident | |
| 3% | Other |
In the line of duty, your biggest danger is heat stress. As your core temperature rises, you lose the ability to concentrate, make sound decisions, and think critically. Today, heat stress contributes to over half of reported line of duty deaths.
When physical exertion leads to accumulation of heat and sweat, your body naturally cools down by allowing sweat to evaporate. Without an escape route for the sweat vapor, it stays trapped against your body.
At Fire-Dex, we’ve discovered that traditional gear fails to cool you down where you need it the most, that’s why we developed AeroFlex®, a groundbreaking leap in firefighter comfort and safety.
THE PEAK OF TECHNICAL BRILLIANCE
We use a breathable, 3-layer composite system that targets the areas of your body where heat becomes most encapsulated, the side seams, armpits, inner thighs, and behind the knees.
These patent-pending VaporLite® Panels allow sweat to evaporate more efficiently than any garment available to the fire service today.
VaporLite® Panel Composites
VaporLite® Panels are built exclusively with our TECGEN71® outer shell, CoreCXP™ 1-layer thermal liner, and your choice of either CROSSTECH® Black, STEDAIR® 4000, or Milliken® Assure™ moisture barrier.
TECGEN71® is the only outer shell that can be paired with a single-layer thermal liner thanks to its exceptional breathability and thermal protection, achieving industry-leading Resistance to Evaporative Heat Loss (Ret) and Total Heat Loss (THL) performance. Choose any composite for the rest of the garment and allow these panels to cool the core.
The first of its kind, our AeroVent® Technology utilizes a patent-pending one-way ventilation design that operates in conjunction with the pressure differential between the outer environment and the microclimate inside your gear, allowing sweat vapor to escape without letting heat inside.
AeroVent® Technology enables you to better regulate your core body temperature, reducing the risk of heat stress and other cardiac-related issues.
Particulate-blocking technology in the vents act as a barrier against potentially harmful carcinogens.
The vents lie within the VaporLite® Panels, with two positioned along the armpits and two placed on the inner thighs, facilitating airflow, and promoting optimal cooling where it matters most.
ACTIVE MOVEMENT
By promoting airflow through dynamic movement, AeroVent® Technology generates a constant cooling sensation. As the wearer becomes more active, increased air circulation within the garment results in a heightened cooling experience.
“I am amazed at how cool I felt. I tried on several occasions to saturate myself with as much convective and radiant heat as possible, then when I moved around, I actually started to cool off. This has never happened in any other set of gear I have worn before. The AeroVent® Technology is amazing.”
- Battalion Chief Chad Christensen, LA County
Proven Protection. Verified Performance.
Multiple independent laboratory evaluations confirm that AeroFlex® is designed to manage heat, support physiological performance, and maintain protection as part of a complete PPE system. Testing focused on extreme thermal exposure, breathability and heat stress, and particulate protection at critical turnout interfaces, validating AeroFlex® performance without unnecessary bulk.
Extreme Heat & Flame Protection
Tested at North Carolina State University's Textile Protection and Comfort Center
Using the PyroMan™ thermal manikin, the gear was exposed to direct flame impingement, approximately 2000°F flames for four seconds, targeted specifically at areas incorporating venting and breathable panel construction.
Result:
0% burn penetration was recorded. The testing demonstrated that AeroVent® Technology and VaporLite® Panels prevent external heat from entering the gear while maintaining protective integrity, even under extreme thermal exposure.
Thermal Comfort & Heat Stress
Tested at Florida State University's ThermaNOLE Comfort Lab®
To evaluate thermal comfort and heat stress, two sets of turnout gear were tested in a lab: one AeroFlex® ensemble and one standard turnout ensemble, both constructed with identical primary composites.
Using a sweating thermal manikin simulating overhaul level workloads, researchers measured core temperature, sweat rate, and overall breathability.
Result:
AeroFlex® delivered measurable improvements in physiological performance, including 0.3°C lower core temperatures and a 33% reduction in sweat rate. Breathability also improved significantly, with 20.5% better intrinsic Ret and 16.2% higher THL, resulting in an overall 20% increase in thermal comfort.
Together, these results show that AeroVent® Technology and VaporLite® Panels help firefighters stay cooler longer, reducing fatigue and lowering the risk of heat stress during extended operations.
Particulate Protection at Turnout Interfaces
Tested at RTI International, Verified by UL
Particulate ingress was evaluated across the coat–pant interface to determine if added material improves overall protection.
Result:
UL Verification confirmed 0% particulate ingress when the SCBA harness is properly engaged, validating the protective integrity of the full AeroFlex® ensemble without the need for additional particulate blocking layers at the coat-pant interface.
READY TO MAKE THE SWITCH?
Invest in AeroFlex® Turnouts, because protecting your
department from the effects of heat stress is priceless.
DESIGN FEATURES
Most turnouts are based on one body type. AeroFlex® turnouts are customized to your unique body type, from wide hips to narrow shoulders and everything in between. A great fit offers increased comfort and mobility, while the unique design features of AeroFlex® offer unmatched breathability and heat stress protection. It's time to ask more from your turnouts.
WHAT FIREFIGHTERS ARE SAYING ABOUT AEROFLEX®
“I have worn it in hundreds of live fire evolutions and in various
environments. As we exit the live burn evolution, the
gear cools quite quickly and it seems to keep me cooler
(core temperature wise) in my lower body than my previous set of gear.
It is quite helpful in lessening overall fatigue.”
- Firefighter Andy J. Starnes, Insight Training LLC
“We went into a commercial fire and noticed a lot
less fatigue while wearing the gear and still
felt comfortable for some time after.”
- Lieutenant Matt Jaynes, Seminole County
“The difference was felt while active. While moving there
was a noticeable difference among the participants
who all described the gear as cooler. This is the first
garment I have tested that addresses the overheating
of the firefighters by reducing heat stress.”
- Firefighter Bradley Smith, Long Beach
"AeroFlex® is light, comfortable, and easy to manipulate.
The thermal protection has been tested several times,
and the jacket holds up well to the daily beating it takes."
- Lieutenant Kimo Naumann, Memphis Fire
“I am amazed at how cool I felt. I tried on several occasions to
saturate myself with as much convective and radiant heat as
possible, then when I moved around, I actually started to
cool off. This has never happened in any other set of gear I have
worn before. The AeroVent® Technology is amazing.”
- Battalion Chief Chad Christensen, LA County