At the Wilson College of Textiles, innovation in textile testing has long been driven by a simple goal: better protecting the people who rely on performance apparel in high-risk environments. Researchers at the Milliken Textile Protection and Comfort Center (TPACC) recently reached a significant milestone in that mission: securing a registered patent for their Dynamic PyroMan technology.

The patented system represents an evolution of the long-standing PyroMan™ test method, introducing movement into a process that has traditionally been static. While the original PyroMan™ manikin has been instrumental in evaluating thermal protective performance, researchers have long recognized a key limitation: real people don’t stand still in a fire.

“Normally, you’re not going to be static in a flash fire,” says John Morton-Aslanis, senior thermal protection scientist and lead researcher on the project. “You’re going to be moving, trying to get out of that environment.”

From static to dynamic: a more realistic test

For decades, TPACC’s PyroMan™ system has simulated flash fire conditions by engulfing an instrumented manikin in flames to measure the performance of protective garments. That testing has provided critical data for industries ranging from firefighting to industrial safety, but it has always represented a controlled, stationary scenario.

All of that changes with Dynamic PyroMan™. 

The newly patented manikin can move, simulating a slow run, while exposed to flames that exceed 1,800 degrees Fahrenheit (1,000 degrees Celsius). That motion introduces a different level of realism, allowing researchers to observe garments’ behaviour under conditions that more closely mirror real-world scenarios. 

“If you think about the Los Angeles Fire that occurred a couple years ago, those firefighters had to work their way out of the fire, and they were exposed for a long duration,” Morton-Aslanis says. “They weren’t just standing there. They were moving. Their jackets were moving. Think about when you’re running, what happens to your shirt? Does it ride up? What happens to your pants? Do they ride up? All of these are things we can’t account for with a static manikin, and that’s what the firefighters are exposed to.”

This capability allows researchers to assess not only fabric performance, but also the integrity of closures, seams, zippers, fasteners and overall design during motion. In some cases, garments that appear intact in static testing may behave very differently once subjected to movement.

“It’s about understanding what really happens,” TPACC Deputy Director Shawn Deaton says. “Dynamic PyroMan helps us get closer to that reality.”

TPACC Director Emeritus and Burlington Distinguished Professor Roger Barker shares a recent example of this: a research project sponsored by the DHS/FEMA Assistance to Firefighter Grants Program. 

“We discovered that Dynamic Pyroman(™) can yield dramatically different predictions of skin burn protection than indicated by static tests,” he explains. “That study showed that, because of air movement created by dynamic pumping action in arm and leg movement, the turnout design and its interface closures are significant factors determining thermal protective performance.”

Engineering real-world motion

The path to this innovation spans more than 25 years of research and persistence. The concept traces back to Roger Barker’s foundational work. Barker, TPACC director emeritus and Burlington distinguished professor, began exploring articulated movement in testing manikins in the late 1980s. 

Turning this vision into reality required overcoming different engineering challenges. The manikin had to withstand extreme heat, maintain structural integrity and move in a controlled, repeatable way, all while preserving the consistency needed for scientific testing.

“Our goal is to always simulate as close as possible to a real-world situation, what a firefighter or other worker, or soldier would be wearing, and doing what they would be doing,” Barker says. “So this really gets us into that realm.” 

The development process took more than two and a half years of focused effort, building on prior research. It required extensive testing, redesign and validation. The result is a first-generation prototype capable of controlled, programmable movement, including adjustable speeds and limb-specific motion.

The value of a patent

For research partners and industry collaborators, the patent represents more than recognition. It provides protection and opportunity.

“With a lot of the work that we do within TPACC, we try to standardize our work and let everybody know what we’ve accomplished,” Deaton says. “So this patent will actually give us a little bit of protection from allowing others to mimic what we’ve done, so that we can maybe license this down the road so that other people can utilize it.”

Practically, this means organizations have the ability to collaborate with TPACC to access currently unmatched testing. At the same time, the university retains control over how the technology is used and developed moving forward.

“It’s an acknowledgement of all the work and the effort that we’ve done,” Morton-Aslanis says. “And yes, we can protect it and we can hopefully commercialize it, but getting the recognition for TPACC and for NC State is very, very important.”

The patented system also reinforces TPACC’s reputation as a leader in advanced textile testing. TPACC has built its identity around developing unique methodologies that push the field forward.

“That’s what makes our center special,” Deaton says. “There are testing houses all over the world that test fabrics with standardized equipment. What we have special with TPACC is unique testing equipment, and this is just another unique piece of equipment that we’re the only ones that have at this point in time.”

Looking ahead: expanding possibilities

Even with a patent secured, the work is never complete. Researchers are already exploring next-generation improvements, including faster and more complex movement patterns that more closely replicate human motion under stress. All the while, interest from industry partners continues to grow.

“Companies are asking when they can use it,” Morton-Aslanis says. “They want to evaluate their fabrics, gear and systems in a more realistic way.”

The demand aligns with a long-standing commitment to serving end users, from firefighters to industrial workers. With the patent, TPACC is advancing its textile testing capabilities and further solidifying its role as a trusted research, innovation and industry partner.

As the technology continues to evolve, so too will its impact, helping ensure the next generation of protective apparel performs when it matters most.