The journey of the Westpac Rescue Helicopter Service’s operations uniforms has been one of constant improvement, driven by practicality, safety, and comfort. From the heavy woollen uniforms of the past to the modern, lightweight gear of today, the evolution is striking.

In the early days, the team used bright yellow Merino wool suits that were hot, heavy, and uncomfortable. These wool suits were soon replaced by American imports, which, while effective, were still not ideal for the Australian climate.

Seeking a more suitable option, the Service approached Rundles Tailoring, a local family-operated Newcastle company, which produced a sample flight suit. The partnership proved successful, and Rundles began tailoring flight suits for the crew.

Over time, the uniforms have seen significant upgrades and enhancements aimed at improving comfort and safety. The introduction of lightweight Nomex material was a game-changer, offering a more breathable, lighter alternative. Originally, the crew wore one-piece suits but later switched to a two-piece design, which enhanced freedom of movement and helped with cooling in the Australian climate.

Today’s uniforms are industry-standard, fully fire-retardant, and provide personal protection that is mandatory in the industry, while offering breathable material to reduce the risk of dehydration. Reflective strips have also been added to the forearms and shins for better visibility on hazardous sites.

Another practical improvement is the addition of Kevlar kneepads. Working in the cabin with restricted height, requires moving around on your knees. Kevlar patches are sewn over the knee pads to enhance durability and offer personal knee protection. Winch gloves have also seen substantial improvements, now lasting multiple winching operations compared to just one or two winch sessions in the past.

For the crew, the uniform is more than just clothing—it’s essential personal protective equipment (PPE) and the first line of defence against fires and the elements. It needs to be comfortable and practical, as it is worn for long periods of time.

Looking back, the transformation of our older uniforms to today’s modern, fit-for-purpose, breathable uniform is undeniable. The advancements have ensured that crews are better protected and more comfortable while operating in the aircraft and performing their critical roles.

While the recommendation is to replace uniforms every two years, the quality of today’s uniforms typically surpasses this recommendation. With a continual process of improvement, the Westpac Rescue Helicopter Service can maintain high standards in both functionality and comfort—essential for a team dedicated to saving lives.