Flight Suit Care and Maintenance: How to Wash, Inspect and Extend Service Life

Proper flight suit care protects both the garment and the person wearing it. Flame-resistant fabric does not lose its protection when it is washed, but contamination, abrasion, and damaged closures can still reduce performance. A simple routine of inspection, correct laundering, and timely retirement keeps a flight suit serviceable for years.

This guide summarizes accepted practice for Nomex® and aramid flight suits, from daily checks to laundry temperatures and storage.

Why Flight Suit Maintenance Matters

Inherently flame-resistant fibers such as Nomex® and aramid have protection built into the fiber. Unlike treated cotton, the flame resistance cannot be washed out or wear away. That does not make the garment indestructible.

Protective performance can still be compromised by:

• Fuel, oil, grease, and solvent contamination
• Tears, holes, and worn or thinning areas
• Damaged zippers, cuffs, and closures
• Excessive shrinkage or fabric degradation from improper heat
• Residue from bleach, fabric softener, or starch

DuPont technical guidance notes that Nomex® garments can remain serviceable well beyond 100 wear and wash cycles, with industrial launderers estimating a service life of about five years under normal conditions. That lifespan depends on correct care and inspection.

Daily and Pre-Flight Inspection

Check the suit before each use, paying attention to high-wear areas:

• Knees, elbows, seat, and cuffs for thinning or abrasion
• Seams and stitching for fraying or opened seams
• Front zipper, leg zippers, and pocket closures for smooth operation
• Collar, sleeve ends, and trouser hems for tears
• Fuel, oil, hydraulic fluid, or unknown stains
• Reflective tape, patches, and rank holders for secure attachment

Remove the garment from service if damage exposes the wearer or if contamination cannot be removed.

How to Wash a Flight Suit

1. Prepare the Garment

Close all zippers and fasteners. Empty pockets and remove badges or items that could damage the fabric. Pre-treat oily or greasy stains, because flammable soils must be thoroughly removed for the garment to perform as intended.

2. Wash Separately

Wash flight suits separately from other clothing, especially cotton and lint-producing fabrics. Lint can contaminate the garment and affect performance. Sort by shade to reduce color transfer.

3. Use the Right Detergent

Use a mild or heavy-duty synthetic liquid detergent. Do not use chlorine bleach, fabric softener, or starch. Oxygen bleach may be acceptable where permitted by the manufacturer, but chlorine bleach weakens aramid fibers and accelerates color loss. Avoid tallow-based soaps.

4. Control the Water Temperature

Wash at a maximum of about 140°F (60°C). Hotter water will not damage the inherent flame resistance of aramid fabric, but it can cause discoloration and faster color loss. Use a normal or gentle cycle with adequate rinse cycles to remove detergent residue.

5. Avoid Overloading

Do not overload the washer. Adequate mechanical action and water circulation are needed to remove oils and soils from the fabric.

Drying and Ironing

Nomex® and aramid fabrics dry quickly and should not be overdried.

• Tumble dry on low to medium heat, or hang dry in a clean, well-ventilated area.
• Avoid direct sunlight for long periods, which can fade the color.
• Remove the garment promptly when dry to reduce wrinkling.
• If ironing is required, use low temperature and do not exceed about 280°F (138°C) fabric temperature. Iron inside out.

Do not use a hot iron directly on reflective tape, patches, or zippers.

Handling Stains and Contamination

Fuel, oil, hydraulic fluid, and solvent stains are more than an appearance issue. Contaminants can burn and may mask the protective performance of the fabric.

• Treat stains promptly and wash the garment thoroughly.
• Use a professional laundry service for heavy contamination.
• Do not return a contaminated suit to flight duty until it has been cleaned and inspected.
• If contamination cannot be removed, retire the garment.

Storage

Store flight suits clean and dry, in a cool, well-ventilated area away from direct sunlight. Use a sturdy, wide hanger to hold the shape of the shoulders, or fold the suit neatly if hanging is impractical. Do not store garments in damp lockers or sealed bags while still moist.

Keep flight suits away from chemicals, solvents, and surfaces that may transfer oil or dye.

Repair and Retirement Criteria

Minor repairs such as a loose seam or a small patch may be possible if they can be made without reducing protection. Repairs should use compatible flame-resistant materials and be carried out by a qualified repair service.

Retire the garment when:

• A tear or hole cannot be repaired safely
• The fabric is thin, worn through, or structurally weakened
• Contamination cannot be removed
• Zippers or closures cannot be repaired
• The garment no longer fits correctly for layering or movement
• The manufacturer's service-life limit has been reached

Managing a Laundry Program

Organizations with large aircrew populations should document laundering and inspection. A simple program includes:

• A unique garment identifier for each suit
• A log of wash cycles and inspection dates
• Defined criteria for removal from service
• Separate processing of contaminated garments
• Periodic audits of laundry providers

Record keeping supports safety compliance and helps procurement predict replacement cycles.

Frequently Asked Questions

Does washing remove the flame resistance from a Nomex flight suit?

No. The flame resistance of Nomex® and aramid fibers is inherent and is not washed out. Protection can still be reduced by contamination or physical damage.

Can a flight suit be dry cleaned?

Aramid flight suits can generally be dry cleaned in perchloroethylene or petroleum solvent without affecting flame resistance. Follow the manufacturer's care label and avoid solvents that leave residue.

How often should a flight suit be washed?

Wash it whenever it is soiled, after exposure to oils or chemicals, and on a regular schedule for hygiene. Clean garments also make inspection easier.

Conclusion

Flight suit care is straightforward but important: inspect regularly, wash separately with the right detergent, control heat, remove contamination, and retire damaged garments.

With correct maintenance, an inherently flame-resistant Nomex® or aramid flight suit can deliver reliable protection for many years. C&G Group supplies one-piece and two-piece flight suits with care guidance for each fabric. For questions about fabric selection or replacement planning, contact our team.