Sewing the seeds of innovation
A journey from dressmaking to cutting-edge defence technology
Yen Truong has woven her passion for materials and precision into a groundbreaking nanofibre suit that could revolutionise protective wear for Australian troops and beyond.
Yen Truong’s childhood memories of watching her mother, a professional dressmaker, meticulously craft garments might seem worlds away from her current life.
Decades later, those early lessons in materials, patterns and precision have unexpectedly helped her in her work here as a chemist.
Now a Team Leader in the Manufacturing Research Unit, Yen is leading a project to develop a next-generation suit. This suit is designed to safeguard Australian troops from chemical and biological threats.
After years of dedicated research and development, the project team recently celebrated a major breakthrough: the creation of a successful prototype suit that passed every test with flying colours.
Engineered to withstand Australia’s harsh climate, the revolutionary suit boasts an innovative, lightweight composite textile structure – shielding wearers from harmful particles without sacrificing breathability or comfort.
The secret weapon? A layer of nanofibres – incredibly light and breathable filaments at least 100 times thinner than a human hair.
Coordinated by DMTC Ltd, the project has already garnered numerous awards. This includes DMTC’s own Most Improved Capability and Team Work awards, along with a Leadership Award for Yen herself.
Recently shortlisted for the Land Forces Innovation Awards, the project continues to garner recognition.
With a chuckle, Yen admits she’s running out of shelf space for any more awards but says she’s incredibly proud of her team’s accomplishments – and the leadership skills she’s honed along the way.
The nanofibre advantage
Yen’s journey into nanofibres began almost two decades ago when the CSIRO Leather Research Centre, where she worked as a research assistant, shifted away from textiles.
“Nanofibre is a remarkably versatile material,” Yen explained.
“We’re using it in this defence project, but we’ve also applied it to diverse areas like battery membranes and peripheral nerve repair.”
Yen highlighted that the advantage of using nanofibre in soldiers’ uniforms lies in it being incredibly lightweight with a high surface area.
“This means the material we have developed provides a high level of protection, while allowing heat to escape the fabric, which is crucial for comfort in extreme temperatures.”
The ambitious project has spanned six years and two distinct phases.
The first stage focused on proving the technology’s feasibility, while the second scaled up the technology to a higher technology readiness level.
Yen said the major achievement during this phase was the successful manufacture of a full 90 metres of the nanofibre-embedded material, which was then fabricated into the prototype uniform.
“The prototype was rigorously tested and met or exceeded all requirements for air filtration, air permeability, thermal comfort, and chemical protection,” Yen said.
She also points out that this milestone demonstrates the potential for scalable production and real-world application of this innovative technology – a common challenge for novel materials.
Scaling up: from lab to fab(rication)
“One of the biggest hurdles we faced was scaling up the technology,” Yen explained
“It’s easy enough to create a composite nanofibre material in a small lab setting, but transitioning to mass production is a different thing altogether.”
Our pilot-scale machine, larger than typical lab equipment, proved invaluable in bridging the gap between laboratory and commercial production.
“We’re able to produce more than just small lab-scale quantities,” Yen said.
“This pilot scale allows us to demonstrate the technology’s potential and then transfer it to commercial manufacturers more easily. It’s like having a stepping stone between the lab and full-scale production.”
This approach minimises the leap needed for commercial partners to adopt the technology, making it more feasible to mass-produce the nanofibre material.
Not just for soldiers
Yen is optimistic about the potential impact of this project, envisioning a ripple effect beyond the defence sector.
“If it gets to a stage where defence has a product on the shelf, then that could easily be extended to other first responders,” she said.
“Firefighters could benefit from lighter, more breathable protective gear that shields them from heat, smoke, and harmful particles. Hazmat crews could have suits with enhanced chemical resistance and filtration capabilities.”
Police and security services could also benefit from extra protection against chemical and biological threats.
“This could also help to spur the growth of a sustainable local supply chain for nanofibre production, stimulating economic growth and technological advancement.”
Collaboration is key
This collaborative effort wouldn’t have been possible without the combined expertise of key partners: Bruck Textiles, who provided their textile manufacturing knowledge; the Defence Science and Technology Group, contributing their defence-specific insights; RMIT University, offering fashion design expertise and testing capabilities; and DMTC Limited, who expertly coordinated the entire project.
“This project is a true testament to the power of collaboration,” Yen emphasised.
“We couldn’t have achieved this without the combined strengths and expertise of each partner. It’s a shining example of how working together can lead to groundbreaking innovation.”
The team is now seeking further funding to move into field trials and continue scaling up the manufacturing process.