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By  Rebecca Willetts 24 September 2024 4 min read

Key points

  • We are developing a next-generation protective suit using nanofibres.
  • The project has successfully progressed from laboratory research to the creation of a full prototype uniform from our novel nanofibre-based material.
  • This technology may have applications extending to many frontline workers including firefighters, paramedics and healthcare workers.

For soldiers on the frontline, chemical and biological hazards are a sobering threat.

Traditional bulky protective suits offer a crucial layer of protection but come at the expense of breathability and mobility. This can lead to discomfort, heat stress and even hinder performance in harsh environments – potentially jeopardising the wearer's health.

Our researchers are working to revolutionise personal protective equipment. We’ve developed a next-generation suit prototype that prioritises safety and comfort for soldiers and first responders.  

Project Lead, Yen Truong (L) and DMTC Head of Program Management Deepak Ganga (R) with uniform model Dan Eyckens

Unravelling the potential of nanofibres

The secret to our breakthrough lies in nanofibres – incredibly fine filaments at least 100 times thinner than a human hair. These tiny wonders have an extraordinary surface area that prevents harmful aerosol particles from passing through. What truly sets them apart is their breathability. Unlike traditional protective materials, nanofibre layers allow air to circulate freely – ensuring the wearer remains comfortable even in extreme conditions.

Senior researcher Dr Yen Truong is leading the project at CSIRO. She explains that nanofibres have the potential to revolutionise the way we think about protective gear. 

“They offer a unique combination of filtration performance while maintaining breathability. The latter represents a challenge that has long hampered the development of effective lower thermal burden protective suits," she says. 

Weave only begun: the birth of NPAC fabric

The Nano Protective Adsorbent Composite (NPAC) project, which was made possible with Federal Government support, began in 2017. 

Our team of scientists at CSIRO worked hand-in-hand with experts from Bruck Textiles, the Defence Science and Technology Group and RMIT University under the coordination of DMTCThis collaboration brought together knowledge and experience in nanotechnology, textile manufacturing, defence science and fashion design. 

The first success was the development of the innovative nanofibre-based fabric. This fabric acts as a barrier against harmful airborne particles while maintaining airflow. Scaling up this technology from the laboratory to commercial production presented a significant challenge.

"It's easy enough to create a composite nanofibre material in a small lab setting, but transitioning to mass production is a different thing altogether," Yen says. 

Our pilot-scale electrospinning machine produces the nanofibre. This larger-than-typical lab equipment played a crucial role in the production of larger quantities of fabric.

Harnessing the power of electrospinning, researcher Heng Taing creates nanofibres that make up our novel material

This demonstrated the technology's potential for commercialisation, paving the way for real-world applications. A major breakthrough came in 2023 when Bruck Textiles, a leading Australian textile manufacturer, successfully produced 90 metres of the fabric. This material was then fabricated into a prototype uniform, which underwent rigorous testing. 

In testing it surpassed performance targets for air filtration, air permeability, thermal comfort, and chemical protection. This meant the suit not only protected the wearer from hazardous substances, but also offered comfort and mobility in demanding situations.

A suit for every emergency responder

The initial stages of the project have been focused on developing a suit for the men and women who serve in our armed forces. However, the potential applications of this nanofibre technology extend far beyond the battlefield. Emergency responders battling blazes, hazmat crews handling toxic spills, and healthcare workers navigating infectious environments could all benefit from this kind of protection.

"We envision a future where firefighters, paramedics and other frontline workers can focus on their critical tasks without being hindered by heavy, cumbersome protective gear," Yen says. 

"Our nanofibre suit aims to provide that level of comfort and freedom of movement while ensuring the highest level of protection."

Team Leader Yen Truong testing the uniform material with a porometer to determine what can and cannot pass through it.

Award winning innovation

The project's innovative approach and promising results have not gone unnoticed. 

The NPAC tech has already garnered several awards. Recently the team’s dedication earned DMTC's Capability Improvement Award and Team Work awards, and was a finalist for the 2024 Land Forces Innovation Awards.

Strengthening Australia's sovereign capability and economy

Beyond safeguarding our first responders, this nanofibre technology has the potential to create a thriving local industry. Establishing a sustainable supply chain for nanofibre production within Australia can reduce our reliance on imported materials – as well as stimulate economic growth and create high-tech manufacturing jobs. The potential of this nanofibre technology also extends far beyond protective gear. 

Nanofibres, with their unique properties and versatility, offer a wide range of applications across various industries. From filtration and energy storage to healthcare and environmental remediation, the possibilities are vast.

The initial phase of this project was funded by the Department of Defence. The successful nanofibre suit prototype was coordinated by DMTC Limited. 

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