What it does
ThermaGuard is a smart cooling vest designed to reduce heat stress for outdoor workers. It uses AI-driven Peltier modules, sensors, and solar-assisted power to actively cool the body in response to real-time environmental and physiological conditions.
Your inspiration
Living in the UAE, we regularly observe outdoor laborers endure long hours in severe heat, often with inadequate cooling solutions. Most existing products are uncomfortable, short-lived, or unsuitable for full-shift use. This inspired us to develop a smarter, scalable solution that merges AI, active cooling, and solar energy into a wearable format. Our aim is to improve worker safety, comfort, and productivity in harsh conditions, while keeping it affordable and practical for businesses to deploy across industries. The vision is to redefine heat protection as an essential part of modern occupational safety.
How it works
ThermaGuard is envisioned as a lightweight, high-visibility vest with embedded thermoelectric cooling modules placed over key heat zones: neck, chest, shoulders, and back. These Peltier modules are intended to be powered by a rechargeable battery, supported by a flexible solar panel mounted between the shoulders. Environmental and body data: temperature, humidity, and motion, would be collected using sensors placed in the collar and chest. An AI-powered microcontroller is designed to interpret this data and modulate each cooling module’s intensity dynamically. To enhance efficiency, passive Phase Change Material (PCM) pads would store excess heat and release cooling over time. The control system, solar input, and battery would be housed in a waist-mounted AI module. The system is imagined to run for a full work shift, even in remote conditions, and designed to be rugged enough for outdoor labor, resistant to dust, sweat, and daily motion.
Design process
The project begins with identifying key limitations in existing cooling wearables—such as short-duration effectiveness, user discomfort, and lack of adaptability to outdoor working conditions. Initial sketches explore core concepts like active-passive cooling integration and modular placement of components. CAD modeling helps visualize cooling zones, weight distribution, and solar panel geometry. We intend to use engineering simulation software to model thermal flow, airflow, and ergonomic fit under various use cases. The prototype will feature off-the-shelf Peltier modules, ESP32 microcontrollers, and commercially available PCM sheets. The AI control unit is being designed for rugged use, with USB-C charging and a clip-on mount. The flexible solar panel is selected to reduce surface heat and extend runtime. We use generative AI tools to visualize the design—creating exploded views, internal layouts, and labeled diagrams to communicate component interaction. Future steps include foam mockups, 3D-printed shells, and electronics integration, with the goal of iterative refinement through lab testing and real-world feedback.
How it is different
ThermaGuard is designed specifically for full-shift use in harsh outdoor environments, unlike consumer devices like Sony Reon Pocket, which offer only short-term, localized cooling. Traditional ice vests are heavy, rigid, and lose effectiveness within hours. ThermaGuard aims to combine active thermoelectric cooling with passive PCMs for long-lasting comfort. What truly sets it apart is its adaptive AI system, which dynamically adjusts cooling intensity in real-time based on environmental and user data. A solar-assisted battery system enables untethered operation, while its rugged design ensures compatibility with PPE and daily industrial wear. At a projected cost of $120–150, it is engineered to be scalable, durable, and practical for companies aiming to protect workers in extreme heat.
Future plans
We plan to move forward with early prototyping and performance validation. This includes controlled lab testing and collaborative field trials with construction and oil firms in the UAE. We aim to pursue CE and ISO safety certifications. Planned upgrades include hydration and UV sensors, filtration collars, and personalized AI profiles based on worker metabolism. We hope to scale across the GCC, Southeast Asia, Australia, and the southern US, partnering with PPE suppliers and regulators to make ThermaGuard a standard for worker heat safety.
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