Integrating Wearable Sensor Networks into Firefighter Uniforms: Design, Development and Evaluation of a Smart E-Textile System

Firefighters operate in hazardous environments characterised by extreme heat, low visibility, and high physical demand. This study presents the design, fabrication, and evaluation of a smart e-textile prototype aimed at improving firefighter safety through real-time physiological and environmental monitoring. A sensor-integrated garment was developed using a 100% cotton base and an Adafruit Circuit Playground Bluefruit microcontroller with pulse, temperature, and motion sensors. The system transmits data to a cloud-based web interface via Bluetooth Low Energy (BLE) for remote monitoring. Evaluation covered comfort, mobility, system responsiveness, and accuracy of sensor data. Results indicated reliable signal transmission and comfort, though challenges remained with sensor alignment and accelerometer-based location accuracy. This research contributes to the growing field of smart protective clothing and outlines a scalable framework for integrating wearable technologies into emergency responder uniforms.