Protecting Workers Year-Round: The Rise of Temperature-Regulating Wearable Technology

April 17, 2025|Clothing, Heat Stress, News & Headlines, PPE, Safety

By Austin Dorman

Evaporative cooling, a technology used in products like the Milwaukee® Cooling Towel shown in picture, creates a cooling effective when the item is soaked in water. Image courtesy of Milwaukee Tool.

In high-heat and cold-exposure environments, employee safety and productivity can be significantly impacted by temperature extremes. Whether working indoors with limited airflow or in outdoor conditions subject to seasonal swings, today’s workforce needs adaptive protection to stay safe and perform at a high level.

Temperature extremes—whether excessive heat or cold—pose significant risks to worker health and job site productivity. Prolonged exposure to high temperatures can lead to heat-related illnesses such as heat stroke, heat exhaustion, heat cramps, and heat rashes. Conversely, cold environments can cause cold-related illnesses including hypothermia and frostbite. In both scenarios, a worker’s ability to concentrate, make decisions, and perform tasks effectively can be severely compromised.

According to OSHA, thousands of workers become ill from occupational heat exposure annually, with some cases resulting in fatalities. From 2011 to 2020, there were an estimated 33,890 work-related heat injuries and illnesses resulting in days away from work, averaging approximately 3,389 cases per year.

Beyond the human toll, these incidents have substantial business impacts, including increased absenteeism, higher error rates, elevated risk of accidents, and operational slowdowns. Implementing effective temperature-regulation strategies is essential for maintaining worker safety, productivity, and overall performance.

Understanding Temperature-Regulating Wearable Tech

Temperature-regulating wearable technology refers to a growing category of personal protective equipment and workwear designed to help maintain safe core body temperatures in both hot and cold environments. These garments include heated jackets, base layers, cooling helmet liners, and sun-protective fabrics—each engineered to assist the body’s natural thermoregulation processes.

Heated gear typically features battery-powered heating elements integrated into the fabric, often positioned across the chest, back, or shoulders. Some manufacturers—Milwaukee Tool, for example—provide the ability to control these elements with adjustable manual settings that allow users to customize heat intensity and duration. Combined with lightweight insulation and weather-resistant outer materials, heated gear is ideal for environments where temperatures drop, and work must continue uninterrupted.

Cooling gear plays a key role in managing heat on the jobsite, using different technologies to support worker comfort and safety. A common cooling technology, known as evaporative cooling – commonly used in products such as cooling towels, helmet liners, and other accessories – is activated by soaking the product in water, which creates a cooling effect as the moisture gradually evaporates. These solutions are lightweight, reusable, and ideal for quick relief in high-heat environments. In parallel, temperature-regulating garments utilize moisture-wicking fabrics that draw sweat away from the body to promote airflow and faster drying.

Modern advancements in textiles and technology have made today’s temperature-regulating wearable technology more efficient, durable, and comfortable. Garments are lighter, more breathable, and better integrated with other personal protective gear—helping safety managers and operations leaders better equip workers for year-round environmental challenges.

The Science Behind It: Materials and Engineering Advances

Workwear that helps maintain safe body core temperatures includes heated jackets, like Milwaukee Tool’s M12™ Heated TOUGHSHELL™ Jacket. Image courtesy of Milwaukee Tool.

The effectiveness of temperature-regulating wearable tech depends heavily on innovations in textile engineering and garment design. Modern performance gear integrates a range of advanced materials to enhance both functionality and durability.

Conductive fabrics—woven with flexible metallic fibers—are the foundation of heated garments. These materials allow for low-voltage electrical currents to flow through heating zones without adding bulk or restricting movement.

Temperature regulating gear, on the other hand, leverage moisture-wicking synthetic blends, often enhanced with antimicrobial treatments to reduce odor and UV-resistant coatings to protect against sun exposure. These fabrics are engineered to dry quickly, allow airflow, and maintain breathability under layers of PPE or in warm environments.

Durability is also key—particularly in industrial environments where garments are subject to abrasion, repeated washing, and extreme conditions. Reinforced seams, stretch panels, and tear-resistant outer shells help these garments perform over time, making them practical and dependable tools for daily use. Together, these material and engineering advances ensure that wearable tech can keep pace with the demands of today’s workforce.

Benefits Beyond Comfort

While comfort is a major advantage of temperature-regulating wearable technology, the real value lies in its impact on safety, productivity, and workforce well-being. Maintaining a stable core body temperature is critical for preventing serious conditions like heat exhaustion, heat stroke, or hypothermia. This gear helps the body release heat during high-exertion tasks or in hot environments, while heated garments protect against cold stress that can impair motor skills and cognitive function.

These benefits directly influence productivity. Workers who are physically comfortable experience less fatigue, maintain sharper focus, and are better able to perform complex or repetitive tasks throughout the day. In many cases, temperature-regulating gear enables longer work durations in challenging environments—reducing downtime and the need for frequent breaks due to discomfort.

From an organizational perspective, prioritizing wearable comfort technologies can also support morale and retention. When workers feel that their safety and comfort are taken seriously, it fosters a culture of trust and engagement. Employers who invest in adaptive personal protective equipment and workwear not only protect their teams from environmental risks but also demonstrate a proactive commitment to long-term workforce sustainability and operational efficiency.

Considerations for Implementation

When evaluating temperature-regulating wearable technology, safety managers and business owners should begin with a clear understanding of their environment-specific needs. Indoor facilities with limited airflow may require different solutions than outdoor settings exposed to extreme seasonal temperatures.

For heated gear, power source logistics are essential—consider battery compatibility, charging access, and runtime requirements to ensure seamless integration into daily workflows. Fit and mobility also matter; garments should allow full range of motion and layer easily under or over existing personal protective equipment without compromising safety or comfort.

Additionally, successful implementation depends on proper training. Workers should understand how to activate, adjust, and care for their gear to ensure long-term performance. Routine maintenance, battery care, and fabric cleaning guidelines are key to maximizing the lifespan and effectiveness of the investment. With the right approach, wearable tech can become a valuable component of a broader safety strategy.

Conclusion

As environmental challenges continue to impact the modern workplace, temperature-regulating wearable technology is emerging as a critical component of proactive safety management. Far from being a luxury, heated and cooling workwear represents a practical, evolving solution—one that forward-thinking safety professionals are increasingly adopting to safeguard their teams and improve overall job performance.

Austin Dorman is Senior Manager Product Marketing at Milwaukee Tool. Since its founding in 1924, Milwaukee Tool has led the industry in developing innovative solutions that deliver increased productivity and unmatched durability. The company is dedicated to delivering advanced, trade-specific solutions, by working with real users to understand the demands of a constantly changing workplace. Milwaukee Tool rethinks solutions and delivers game-changing innovations. https://www.milwaukeetool.com/products/safety-solutions/cooling, https://www.milwaukeetool.com/products/work-gear/heated-gear