Firefighters want a new uniform design that will reduce the weight of the protective clothing as well as provide better protection from a variety of hazards. Innovative fabrics, such as unique nonwovens, must be incorporated into new designs to achieve maximum protection and a reduction in weight. Based on interviews with fire fighters and the types of innovative nonwoven fabrics acquired, two half-scale prototypes in conjunction with a separate half-scale prototype sleeve were constructed. Each prototype incorporated a different closure option and a pouch for the breathing apparatus. The quilted thermal barrier is composed of a needlepunched nonwoven with the moisture barrier being of Nomex IIIA. The prototype sleeve has an innovative feature in the cuff lining that incorporates a very soft and flexible silicon rubber with small magnets to provide a seal between the cuff and glove. These prototypes are evidence that lightweight body-hugging protective clothing can be constructed, giving maxium flammability protection to the wearer.