When it comes to flying, some passengers plan their outfits down to the last detail, while others dress purely for comfort.
Either way, it’s worth taking a quick look at the fabric label before you head to the airport, because one clothing expert says what you wear could affect how you fare in an emergency—particularly if there’s a fire.
The chance of being involved in a plane crash is said to be around 0.000001%, according to Bagget Law Personal Injury Lawyers. It’s not something most people want to think about when they travel, but unexpected situations can happen, and fire is one of the biggest concerns.
Noor de Swart, Founder and CEO of Super Label Store, has shared advice on which materials to avoid on flights—and what to choose instead.
“Most people pick their flight outfit based on comfort, and that usually means reaching for something stretchy like leggings or a polyester hoodie,” de Swart says.
“What they don’t realize is that synthetic fabrics like polyester, nylon and acrylic can melt directly onto the skin when exposed to high temperatures.” Yikes.
That risk isn’t just theoretical. In high heat or open flame, many synthetic materials can ignite and keep burning, and some can soften and fuse to the body.
As de Swart continues: “Some will also melt onto the body. Injuries from that kind of burn are often severe, because the molten material goes on transferring heat to the skin long after the flames have died down.”
The key issue is how different fibres react when temperatures spike.
Synthetic fabrics are effectively plastic-based, and plastics are designed to melt under enough heat. So if a polyester top is exposed to flames, it may not simply burn away from the skin.
Instead, it can liquefy, adhere to the body, and continue to burn.
“Natural fibres like cotton, wool and linen will char, but they won’t melt, and that is a crucial difference,” she explains.
“A cotton T-shirt might catch light, but it won’t bond to your skin. A polyester blend will.
“Once molten synthetic gets into a burn wound the scarring is far worse, because the fabric itself becomes part of the injury.”
Even a brief flare-up can be enough for melting to occur, which is why de Swart argues synthetic-heavy outfits can be especially risky in a confined cabin environment.
Different synthetics can also behave in different ways. Nylon, for example, tends to melt at a lower temperature than polyester and can drip as it burns—potentially carrying heat and burning material further down the body. Acrylic, meanwhile, can ignite rapidly and burn intensely.
“The safest approach is to avoid all of them when you fly,” de Swart says. “If you do wear one synthetic layer, make sure it is not sitting directly against your skin. A cotton base layer underneath makes a real difference.”
So what’s a smarter choice for your next trip?
De Swart’s main recommendation is to stick with natural fibres whenever you can.
“Cotton, wool, linen, even silk are all far safer options,” she says. “A pair of cotton joggers and a merino wool jumper will keep you just as comfortable as any synthetic activewear, and they behave in a completely different way if exposed to flames.”
She also suggests bringing an extra layer like a large cotton or silk scarf, since cabins can get cold and covering your neck can help you stay comfortable. Natural fibres are typically more breathable too, which can make it easier to manage your temperature across longer journeys.
And even on short flights, the advice still applies.
Aircraft fires can spread fast when they occur, leaving little time to react. You don’t get the luxury of time to change what you’re wearing,” she concludes.
“What you have on when you board is what you have on if something goes wrong, so it pays to think about it before you leave the house.”