The objective of the project was to develop an economic fire suit, a turnout gear, based on the research and understanding of all the aspects of design process. The outcome was the EN 469, a lightweight, certified turnout gear, with better durability, improvised breathability and enhanced mobility. The turnout gear consisted of three layers: the outer shell made of Nomex IIIA fabric, the moisture barrier made of PTFE laminated aramid felt and the thermal barrier, made of viscose and meta-aramid blend quilted with aramid felt. The turnout gear was made cost effective by designing the patterns so as to minimise fabric wastage by increasing the marker efficiency.