Conventional protective workwear often reaches its limits during strenuous physical activity. In particular, the transport of sweat and excess body heat poses a problem. The German Institutes of Textile and Fiber Research (DITF) conducted research on flow-optimized, air-conducting textile structures that enable targeted climate control directly on the body. These structures can be integrated straight into protective work garments. The textile climate control system supports the body’s natural thermoregulation. This contributes to improved workplace safety and comfort.
To power the air-conducting structures, pneumatic pressure generators were developed that utilize the body’s everyday movements. For example, a compressible insole in the shoe generates compressed air from the normal act of walking. This allows the system to operate independently without an external compressed air connection. The air volume generated while walking is routed via a hose system in work protective pants to the climate control element in the upper garment. A specially designed belt buckle allows the pants to be intuitively detached from the upper garment during the workday, thereby interrupting the airflow.
The project demonstrated that combining air-conducting textile structures with pressure generators significantly improves heat and moisture management. This not only reduces the risk of overheating but also has a positive effect on wearing comfort and work performance.
The project was carried out in cooperation between DITF and Hero Textil AG. It was funded as part of the Central Innovation Program for SMEs
(ZIM) by the Federal Ministry for Economic Affairs and Energy on the basis of a decision by the German Bundestag.
The StAirS textile climate control system was selected as a successful project example for the 2026 SME Innovation Day in Berlin and will be presented there on June 11 jointly by DITF and Hero. With the Innovation Day, the Federal Ministry for Economic Affairs and Energy is creating a meeting place to showcase innovative projects, new technologies, and creative ideas.
