For decades, personal protective equipment (PPE) procurement has relied on outdated sizing systems that often prioritised convenience over precision. In firefighting in particular, this has had serious consequences. Ill-fitting PPE does not simply reduce comfort; it can compromise mobility, increase heat stress, allow smoke ingress, and potentially contribute to long-term health risks such as cancer exposure. Across global fire and rescue services, the demand for a smarter and more inclusive approach to sizing is driving the adoption of AI powered, 3D body scanning, and mobile-based measurement technologies.
Recent discussions from the PCIAW Improving Firefighter Safety Round Tables reveal a growing consensus that the future of firefighter PPE lies in “fit-for-form” solutions rather than traditional gendered sizing systems. These conversations have highlighted how digital innovation is transforming procurement processes, making PPE sizing faster, more accurate, and more accessible for diverse workforces.
The Problem with Traditional PPE Sizing
Historically, PPE sizing systems have been based on limited anthropometric data and simplified grading structures. Many firefighters, particularly women and individuals outside standard body proportions, are forced to wear oversized or poorly fitted equipment. The consequences can be dangerous. During the PCIAW Round Table discussions, one active female firefighter described how an ill-fitting glove fell off during use because it had merely been scaled down from a male design rather than properly shaped for the female hand.
The issue extends far beyond comfort. Research presented during the round tables connected poor fit to increased cancer risks, particularly among female firefighters. Smoke and carcinogenic particles can enter gaps in poorly fitted garments, while ill-fitting equipment may increase pressure on sensitive areas of the body. This is especially concerning given the World Health Organization’s classification of firefighting as a carcinogenic profession.
Traditional sizing systems also fail to reflect the changing demographics of modern firefighting. Fire services now include more women and people from varied ethnic backgrounds, creating a wider range of body shapes, heights, and proportions that cannot be addressed through standard small-medium-large systems alone. Participants in the 2025 PCIAW session argued that firefighters should no longer be separated into “male” or “female” PPE categories, but instead be provided with equipment that fits their individual form regardless of gender.
The Rise of 3D Body Scanning
To solve these issues, PPE manufacturers and technology companies are increasingly turning to 3D body scanning systems. These technologies create highly detailed digital models of the body, capturing proportions and measurements far more accurately than manual tape measurements.
One body scanning company presented during the PCIAW discussions demonstrated how their scanner can penetrate clothing while generating a full 3D body cloud. This allows precise measurement of factors such as waist-to-hip ratios, shoulder width, posture, and body shape variation. Their findings revealed enormous diversity within firefighter populations. Approximately 66% of the women scanned had a waist-to-hip ratio below 0.8, significantly different from typical male body structures.
This data matters because PPE must work dynamically with the body during movement and under extreme conditions. A jacket designed with shoulders that are too broad can extend sleeve length excessively, forcing alterations that may compromise protection. Similarly, boots designed from male shoe lasts may fail to support female foot structures correctly. These issues affect performance, mobility, and long-term safety.
The integration of body scanning into PPE procurement marks a significant shift away from reactive sizing toward data-driven design. Instead of adjusting garments after production, manufacturers can now analyse body data early in development to build better-fitting equipment from the start.
AI-Powered and Mobile-Based Measurement
There are a range of technological approaches that can further the development based on logistical needs in the industry. This is where predictive AI systems are becoming revolutionary.
One of the most significant innovations discussed during the 2025 PCIAW round table was a predictive measurement platform that uses AI trained on hundreds of thousands of global body scans. Rather than requiring specialist equipment, the system only asks users to answer a few questions through a mobile phone interface. Using global datasets and predictive algorithms, the technology estimates accurate body measurements and recommends the correct PPE size.
This approach dramatically improves accessibility. Firefighters in rural areas, on-call personnel, or departments without scanning infrastructure can still access accurate sizing recommendations remotely. The process is faster, less invasive, and significantly more scalable than traditional fitting methods.
The system also identified a major issue within existing PPE standards: roughly 20% of participants were too small for the smallest standard size currently defined by EN 469. This finding demonstrates how outdated sizing standards exclude a substantial portion of the workforce. High-tech AI allows manufacturers to recognise these gaps and redesign systems around real-world body diversity rather than historical assumptions.
Importantly, AI algorithms do more than recommend sizes. They can generate digital avatars that simulate how garments interact with different body types, helping manufacturers evaluate fit, layering, and movement before physical production begins. This creates opportunities for faster prototyping, reduced waste, and more cost-effective production cycles.
Smarter Procurement Through Data
Digital sizing technologies are also reshaping procurement strategies. Traditionally, PPE procurement has often been driven by standardised bulk ordering, leading departments to purchase limited size ranges that fail to accommodate everyone effectively.
AI introduces a more personalised procurement model. Departments can gather anonymised sizing data across entire workforces and use analytics to identify the actual distribution of body shapes within their teams. This enables smarter inventory management and reduces the need for costly post-production alterations.
The implications for compatibility are also significant. Previous PCIAW discussions highlighted how fragmented procurement during the 2008 financial crisis led to mismatched PPE systems with poor compatibility between boots, gloves, trousers, and jackets. Better digital measurement systems could support the development of universal sizing standards and improve interoperability across manufacturers.
In the future, procurement may become increasingly predictive rather than reactive. AI systems could forecast sizing requirements for incoming recruits, monitor fit changes over time, and recommend re-scanning intervals based on age, physical development, or even pregnancy-related body changes. One footwear scanning specialist at the round table noted that women’s bodies can change significantly throughout their lives, suggesting annual re-scanning to maintain optimal fit.
Challenges and Ethical Considerations
Despite the promise of AI, several challenges remain. Privacy concerns are significant, particularly when collecting body measurements and health-related data. Firefighters and unions may question who owns this information, how it is stored, and whether it could affect fitness-for-duty decisions.
There are also concerns about algorithmic bias. Predictive systems are only as effective as the datasets they are trained on. If body scan databases lack diversity across ethnicity, gender, geography, or age groups, recommendations may still exclude certain populations.
Education is another major barrier. Several participants in the PCIAW sessions noted that many firefighters remain unaware that more advanced sizing options already exist. Manufacturers, procurement teams, and fitting personnel all require training to understand how to interpret and apply digital sizing data effectively.
A New Era of PPE Design
The move toward AI and digital body scanning represents more than a technological upgrade; it signals a complete rethinking of PPE design philosophy. Instead of expecting firefighters to adapt to standardised equipment, the industry is beginning to design equipment around the real diversity of human bodies.
This transition could have profound effects on firefighter health and safety. Better-fitting PPE can reduce smoke ingress, improve thermal management, increase mobility, and minimise fatigue. It may also play a role in lowering long-term cancer risks linked to contaminant exposure and poor garment interfaces.
