Researchers at the German Institutes of Textile and Fiber Research (DITF) have developed a textile-based climate control system designed to improve comfort and safety for workers performing physically demanding tasks while wearing protective clothing.

The new technology, called StAirS, is designed to manage excess body heat and moisture by using airflow-optimised textile structures integrated directly into garments. According to the researchers, the system helps support the body’s natural cooling process, reducing the risk of overheating and improving comfort and productivity in industrial work environments where conventional protective clothing often provides limited ventilation.

The StAirS system works by directing air across the body through specially engineered textile channels embedded within the garment. This continuous airflow helps remove excess heat and sweat, creating a more comfortable microclimate for the wearer.

To enable the system to operate independently without external power sources, DITF developed pneumatic pressure generators that are activated by normal body movements. A specially designed compressible insole placed inside the worker’s footwear generates compressed air while walking.

The research team also developed a specialised belt buckle that allows workers to quickly disconnect the upper garment from the trousers whenever needed. This feature enables users to temporarily stop the airflow system during breaks or while adjusting their clothing.

The project was carried out in collaboration with Hero Textil AG. Financial support was provided through the Central Innovation Programme for SMEs (ZIM), funded by the German Federal Ministry for Economic Affairs and Energy with approval from the German Bundestag.