In 2024, Fire-Dex released a new line of PPE for firefighters with the goal of increasing the safety and functionality of turnouts. In the time since, AeroFlex has proven to be an innovation unlike anything the world has yet seen. This daring new design bridges a gap in firefighter safety, changing the conversation around what it means to support firefighter health and safety.  

Many firefighters have questioned how well AeroFlex can keep them safe on the fireground, wondering if the breathability of the radical AeroVent Technology and VaporLite Panels will hold up during the heat of battle. 

As Derek Currao, a firefighter and instructor with MissionCIT puts it, “Everyone's obviously main concern is, ‘how does it hold up? Is it actually going to protect me?’” 

We designed AeroFlex to maximize safety and pass all NFPA requirements, but the real test of the gear’s performance came when we let firefighters across the country put it through real-world conditions. 

Why Create AeroFlex?  

Turnout gear manufacturers have followed a largely unchanged trajectory for the past several decades. Some would say, “if it ain’t broke, don’t fix it.” But for us here at Fire-Dex, how it’s always been isn’t ever good enough. 

The Importance of Understanding THL and TPP 

For decades, many firefighters only paid attention to the Thermal Protective Performance (TPP) of their gear. TPP refers to the length of time it takes to receive a second degree burn through the three layers of a turnout. According to the NFPA, the minimum TPP score for turnout gear is 35. That translates to a time of 17.5 seconds.  

However, TPP is not the only important factor in keeping you  safe.  

THL, or Total Heat Loss, measures turnout breathability. Breathability allows hot air to escape through cloth and cool down your body. According to the NFPA, heat stress and overexertion are the number one causes of LODDs for firefighters, accounting for 65% of line of duty deaths.  

TPP and THL are often a tradeoff. A suit of armor four feet thick would have incredible TPP but extremely poor THL. So, while you might be protected from the flames, you’re in danger of harm from heat stress and overexertion.  

So, while TPP is undoubtedly important, so is THL. 

Searching for Balance 

When we saw the shocking statistics about deaths caused by heat stress, we knew we had to do something. Preventing burns from the outside-in shouldn’t mean you have to accept burning from the inside out.  

So, when our design experts set out to correct this problem, they searched for a balanced approach; combining excellent TPP with THL that actually changes the reality of heat stress damage.  

AeroFlex Put to the Test 

AeroFlex was created to combat the devastating reality of LODDs from heat stress that still exists in the lives of real firefighters. Our experts put their heads together and AeroFlex was the result. The only question left is—does it actually work? 

In the Lab 

We sent AeroFlex turnouts to independent laboratories to showcase their performance. 

To test the protection of the VaporLite Panels, North Carolina State University exposed them directly to flames. The result? 0% third-degree burns, demonstrating that the gear protects from fireground dangers.   

For breathability, Florida State University put the gear on a sweating mannikin. When the mannikin simulated overhaul activities in AeroFlex, it performed much better than a similar set of gear without AeroVent technology, showing a significant decrease in sweat rate and core body temperature.  The testing also showed how the features in AeroFlex contribute to a 20% increase in thermal comfort. 

In the Real World 

Lab testing is one thing, but feedback from real firefighters is another. That’s why we reached out to those of you who use AeroFlex and asked for your genuine feedback on this revolutionary product. From intense training, to extrications, to structural fires, to live burns, AeroFlex has proven worthy. 

Florida Firefighter Jimmy Berry says AeroFlex extends his active working time. He says, “You don't get heat saturated as fast,” which makes a huge difference in efficiency on calls. 

Confirming this sentiment, Derek Currao, explains that AeroFlex’s breathability makes a difference in his operational time. Confirming the science behind THL, he says, “There's a lot of gear out there that is like a suit of armor. You could set yourself on fire and it can protect you, but your operational time is diminished because it's like a giant sauna inside.”  He says AeroFlex is the best of both worlds, protecting him during a close call on the fireground while still allowing him to operate with more efficiency. 

According to Ohio Firefighter and Founder of Female Firefighters of Ohio, Alexandria Brown, AeroFlex gives her an edge. She says with the gear, “I am training longer, and I am not as fatigued when I am done just because it is lighter and I am not getting as hot.”   

Fire Captain Peter Morotto of Mission CIT attests to the necessity of physical mobility and speed in firefighting— “Being fast on the fireground is going to save somebody's life. And if I could be comfortable and confident in my equipment to move quickly and efficiently, that to me is what's going to make the difference.” AeroFlex lets him do his job in a safe and effective way. 

AeroFlex provides superior safety in ways that no other turnout gear has. By considering the importance of both TPP and THL, Fire-Dex was able to create a product that protects from inside and out, giving firefighters the edge to success on the fireground. Backed by science and testimony, AeroFlex is fulfilling our promise to “Serve Those Who Serve,” protecting first responders while helping them perform at the top of their game. 

Will your next set be AeroFlex?