Shopping Cart [ 0 ] October 24, 2024
The Hidden Dangers of Heat for Costumers, Cosplayers, Furry's and Performers
Heat is more dangerous than most of us realize, especially for those spending long hours in costumes. Globally, heat causes more deaths each year than hurricanes, tornadoes, and floods combined, yet it’s rarely treated as the deadly threat it is.
Despite its severe impact, no heat event has ever been classified as a natural disaster by the U.S. Federal Emergency Management Agency (FEMA), leading many to underestimate its risks.
One critical factor to keep in mind is the heat index, which combines air temperature and humidity to reflect how hot it feels to the human body. While a thermometer might say it’s 85°F (29°C), the heat index can make it feel much hotter – sometimes dangerously so.
Did you know that humans have a heat stress threshold of 85°F (29°C)? Once the heat index surpasses this, our bodies struggle to dissipate heat and cool us down making simple tasks feel exhausting. When the heat index hits 95°F (35°C) our work output drops by 45%.
Heat stress doesn’t just make you sweat – it forces your heart to work overtime to regulate your body temperature, which can have serious long-term consequences. Repeated exposure to heat, especially in costumes or heavy gear, puts immense strain on the cardiovascular system. Over time, this can exacerbate existing heart conditions and lead to chronic health issues. Studies show that repeated heat stress can cause or accelerate heart problems, even for people without preexisting conditions.
The result? Long-term damage that builds quietly and may not be noticed until it’s too late.
The effects of heat stress extend beyond the heart. Prolonged exposure to high temperatures can damage kidneys, impair cognitive function, and lead to severe dehydration. Heat can cause persistent fatigue and, in extreme cases, it can be fatal. The heart, however, remains the primary concern—heat forces it to pump harder and faster, increasing the risk of cardiac events.
According to the U.S. Center for Disease Control (CDC), heat directly kills around 1,200 people each year in the U.S. alone, a number that’s risen from 700 just a few years ago. But experts believe the true number is much higher, likely around 10,000 annually. Why the discrepancy? Because heat is rarely listed on death certificates. When people die from complications exacerbated by heat – whether from heart failure, stroke, or even complications from conditions like Alzheimer’s – heat is often not officially noted as the cause.
The link is clear: hot weather leads to more cardiac arrests, strokes, and diabetes complications. It aggravates neurodegenerative diseases and worsens the health of people with existing medical conditions. The consequences are serious, often deadly, and far-reaching. Understanding these risks is the first step toward protecting yourself, especially costuming in hot conditions.
Think back to your last hot outdoor event this summer – maybe a day at an amusement park, an all-day family gathering, or camping. Perhaps it was something like the Renaissance Festivals, Shakespeare in the Park, theater on a stage, or a parade. It was fun in the sun, but the next day, you felt wiped out, fatigued, weak, and even a bit nauseous. You might have thought you just “overdid it” or regretted that extra corn dog. While overexertion and that extra treat might have played a part, the real reason you felt unwell is likely the heat. Many people don’t fully grasp how much heat can impact their bodies.
The human body is like a fine-tuned machine that needs to operate within a specific temperature range for optimal performance. It's a Goldilocks situation: not too hot, not too cold, but just right. When our core temperature gets out of the 92 ̊F to 104 ̊F (33°C to 40°C) range, it can lead to some scary and dangerous symptoms.
For example, hypothermia, or being too cold, starts when our core temperature drops to 92°F (33°C). At 80°F (27°C), our heart and lungs can no longer function. On the flip side, hyperthermia, or heat stroke, begins when our core temperature hits 104°F (40°C). If it reaches 109°F (43°C), our brain can shut down.
Let’s dive into a quick lesson on how our bodies handle heat. Our bodies use four main mechanisms to regulate temperature: convection, radiation, conduction, and evaporation.
First up is convection, which is the transfer of heat through air. For example, heat rises from the ground and your body absorbs it, causing your core temperature to rise.
Next is radiation, the transfer of heat through space in the form of invisible energy waves, like infrared light.
Think of the sun’s heat. When you’re in costume, your outfit absorbs this radiant heat just like a dark t- shirt does on a sunny day.
This is especially noticeable during events like parades, Pennsic War, Colonial Williamsburg, or Renaissance Festivals.
Conduction is the transfer of heat through an object or between two objects in direct contact. For instance, heat from hot pavement is conducted to your body.
Remember, heat always moves from the hotter object to the cooler one.
Finally, evaporation is how sweat on your skin turns into vapor, helping to cool you down by carrying away excess heat. We rely heavily on this process to regulate our body temperatures.
Sweating alone doesn’t cool you off – sweat is the same temperature as your core temperature 98.6 ̊F (37 ̊C). Instead, it’s the evaporation of sweat that cools your skin. Think of your skin as a radiator: hot blood moves to the surface, making you sweat. The wind then evaporates the sweat, cooling your skin and blood, which helps maintain a steady core temperature.
Imagine sitting on your porch on a partially sunny 70°F (21°C) day with a gentle breeze – it’s relaxing. Now picture sitting on the same porch on a 90°F (32°C) day with intense sun and a hot breeze–it’s not comfortable at all. The difference is heat stress. Your core temperature and heart rate are rising. For every degree your internal temperature increases, your heart beats about 10 beats per minute faster, putting extra stress on your heart.
As your body overheats, it works harder to cool down by dilating blood vessels, which increases blood flow to the skin and makes you sweat. This can lead to breathlessness, especially for those with asthma or chronic obstructive pulmonary disease (COPD), and can also cause issues like low blood sugar for diabetics and dehydration, which might result in dizziness and fainting.
So, on that hot day, when you feel wiped out after being in the sun, it’s because your body has worked hard to keep you cool even if you don’t always “feel” the increase in heart rate or core temperature. This is how heat causes fatigue.
Recognizing signs of overheating, heat exhaustion and, heat stroke – such as heavy sweating, cold or clammy skin, a fast weak pulse, nausea, muscle cramps, dizziness, headaches, or fainting – is crucial. However, these signs can be vague and easily brushed off. Nausea? I shouldn’t have eaten that corn dog. Dizziness? I was spinning really fast when I was dancing. Headache? I didn’t have my cup of coffee this morning.
Overheating can happen gradually or suddenly, and in severe cases, it can be fatal. Therefore, it’s important to address your core temperature rather than just the symptoms of overheating.
Our bodies generate heat as a by-product of energy production. When we’re in costumes that trap this heat, it can create a high-humidity environment where sweat can’t evaporate, making things worse. If your costume doesn’t allow for sweat evaporation, it will make you hotter every time.
As sweat accumulates, humidity inside the costume quickly rises from 20% to 100%, at which point evaporation stops entirely. The combination of heat and high humidity, along with activity and heavy costumes, can create dangerous conditions, increasing the risk of heat-related illnesses for actors and performers. Even in indoor settings, hot studio lights and poor ventilation can contribute to heat stress.
High-Risk Roles
Heat presents an even greater challenge for those in high-risk roles—particularly actors and performers who wear heavy or non-breathable costumes, often for hours at a time.
Peter Mayhew, who portrayed Chewbacca in the Star Wars films, faced significant overheating issues while filming in his iconic Wookiee costume. Made of yak hair and mohair attached to a knitted wool suit, the costume was not only cumbersome but incredibly hot, especially during desert scenes in Return of the Jedi. The production team had to take extra precautions, ensuring Mayhew stayed hydrated and cool between takes to prevent heat exhaustion.
Kenny Baker, who brought R2-D2 to life in the original Star Wars trilogy, also endured extreme heat. The small, enclosed space of the R2-D2 suit, coupled with the sweltering desert locations, created a virtual oven for Baker. He often felt faint and had to be removed from the suit to cool down, with the crew developing special cooling methods to help him get through his scenes.
Michael Keaton had a similar experience while filming Batman Returns. The heavy rubber Batsuit, designed to look imposing on-screen, was nearly suffocating for Keaton, trapping heat and preventing ventilation.
His discomfort was so intense that the production team had to schedule frequent breaks and develop cooling techniques just to keep him functional on set. Keaton has spoken in interviews about how grueling it was to perform under such conditions, with the risk of overheating a constant concern.
These challenges aren’t limited to blockbuster film sets. Performers in theme parks, Renaissance festivals, and outdoor events, such as cosplayers and fursuiters, often wear full-body costumes that make it difficult to regulate their body temperature. Studies by the U.S. National Institute for Occupational Safety and Health (NIOSH) have highlighted the prevalence of heat stress among outdoor costumed performers, emphasizing the critical need for effective cooling measures. Reports from conventions and events frequently cite instances of heat exhaustion in performers, underscoring how serious the issue of heat stress truly is.
For costumed performers in high-risk roles the dangers of heat stress are even more pronounced. Remember the human heat stress threshold? When the heat index exceeds 95°F (35°C) work output can plummet by as much as 45%. This means performers are not only giving 45% less to their performance, but they’re also putting their health at serious risk.
The energy, focus, and physical ability needed to deliver a full performance are severely compromised, turning what should be a creative expression into a potentially dangerous situation. At these temperatures, staying cool isn’t just about comfort—it’s essential for safety and well-being.
Take a look at these photos from Midwest FurFest showing Furries walking around the Dealer's Den. In the first thermal image, the maximum temperature is 103.7°F (39.8°C), especially noticeable in the bright yellow and white areas like the head and armpits. Heatstroke starts at 104°F, so this furry is just a fraction away from serious heat issues and likely experiencing some heat exhaustion symptoms such as excessive sweating, headache, and dizziness. And remember, they’re just walking around, not dancing or exerting themselves.
Now, check out this other furry in the Dealer's Den. The maximum temperature here is 105.3°F (40.7°C) well into heatstroke territory, which begins at 104°F. This furry is most likely experiencing classic signs of heatstroke: hot, red, or dry skin, a rapid pulse, headache, confusion, nausea, and dizziness. Without immediate cooling relief, this situation can become life-threatening.
Inside a furry headpiece after it’s been removed, it’s 92.4°F (33.5°C) inside! And that’s after taking it off—imagine how much hotter it gets when it’s back on, combined with body heat and sweat, pushing temperatures well into the 100°Fs (high 30°Cs).
You might be wondering if this affects other types of costuming. Absolutely – it’s not just Furries who face this issue! Take this historical costumer (right), for example. In an air-conditioned space during a photoshoot, she starts overheating at 101.2°F (38.5°C) without a cooling vest.
After putting on the cooling vest, her body temperature begins to drop almost immediately, showing just how crucial these cooling solutions are for anyone in elaborate costumes.
Let’s dive into another key piece of the heat puzzle: Environmental Conditions. We’ve got, temperature, humidity, direct sun and air movement but what about those sneaky heat sources like hot lights or relentless sun?
And let’s not forget the real kicker for costumers at conventions—the Masquerades and performing on stage.
Imagine a skier out in the snow, fully geared up in long johns, snow pants, a heavy coat, gloves, boots, and a helmet—now imagine them dancing away in that outfit with no chance of staying cool. That’s what it’s like for costumers trying to keep their core temperature down.
Think back to your last Masquerade or Renaissance Festival where you were decked out in your full costume and pushed it a bit too far. You probably felt pretty warm, sweated buckets, and that last few minutes were a real struggle. The next day, I bet you were exhausted. What you are experiencing is heat stress, just like sitting on the porch in 90-degree weather—heat wears you out.
The good news? Many heat-related issues we’ve talked about are preventable. But some things, like health conditions and medication interactions, are not. As we age, our risk for heat-related issues increases.Got asthma, high blood pressure, or diabetes? These conditions can worsen in the heat. Diabetics struggle with temperature and blood sugar regulation. Heart disease increases the risk of heart attacks, and asthma or COPD can make breathing tougher. Even mental health can take a hit; there’s evidence of higher rates of suicide, homicide, and violent crime on extremely hot days.
Also remember that medications – allergy meds, antidepressants, beta blockers – can all come with side effects that affect how the heat sensors in your brain handle the heat. Please, talk to your doctor about how your medications might interact with the heat.
So, how hot is it really? To figure that out we need to know more than just the ambient air temperature. Did you know the daily official temperatures are taken in the shade and that direct sun can add 15°F (8.3°C) to the ambient air temperature?
Some Weather Math
For low-humidity situations like indoor Masquerades or stage performances, the heat might not be as extreme, but it’s still significant. In a room with an ambient temperature of 70°F (21°C), adding lights and nerves (+15°F, +8.3°C), costume (+5°F, +2.8°C), and age, health, and medication (+5°F, +2.8°C), will easily push the temp to around 95°F (35°C)!
For a high-humidity outdoor event in the sun in Atlanta in July, the “Feels Like” temperature (Heat Index) is 101°F (38.3.°C). Factor in direct sun (+15°F, +2.8°C), costume (+5°F, +8.3°C), and age, health, and medication (+5°F, +8.3°C), and you’re looking at a potential 126°F (52.2°C)! I know, it sounds extreme, but hear me out.
Here’s your heart temperature. This is the temperature that your heart is calculating while trying to cool your body.
• Low humidity situation: Feels like 70°F (21°C) but our heart is calculating it at 95 ̊F (35°C).
• High humidity situation: Feels like is 101 ̊F (38.3.°C) but our heart is calculating it at 126 ̊F (52.2.°C).
I know that 126 ̊F (52.2.°C) looks crazy...and it is. That is a recipe for Heat Stroke or death. No one should be performing in that kind of weather in a costume.
So, what can you do to help your body and heart stay cool? Let’s explore some cooling options. Cooling vests come in various styles, each with its own set of benefits and drawbacks:
Gel Pack Cooling Vests
These vests use cooling sheets that need to be soaked and frozen. They’re relatively inexpensive but can feel slimy and have limited longevity. They also tend to create condensation, which can make both you and your costume damp.
Embedded Gel Cooling Vests
Lightweight and easy to use, these vests contain hydrogel crystals that activate when soaked in water. While they’re among the lightest options, they typically last between 30 minutes to an hour and can be damp, which may not be ideal for prolonged use.
Ice Pack Cooling Vests
While heavier and bulkier they are inexpensive, simple and, effective. These vests use frozen ice packs. While they provide reliable cooling for several hours, they can cause frostbite if worn directly against the skin and can also make your costume wet.
Evaporative Cooling Vests
These vests work by soaking in water and then wring out. They are easy to use but have limited cooling time and can make your costume wet. If you wear a full-body costume, never wear Evaporative Cooling Vests under your costume. They will contribute to the humidity in your costume and will make you hotter instead of cooling you down.
Active Cooling Vests
The most advanced and expensive option, these vests use recirculating chilled fluid to keep you cool. They offer excellent cooling but are not very portable and require a power source, making them less practical for most costume activities. The wires, fans, and noise they generate also make them difficult to use on movie sets.
PCM (Phase Change Material) Cooling Vests
PCM cooling vests cool through conduction, offering reliable relief even in hot, humid environments where other cooling methods struggle. The PCM packs in the vest absorb body heat as they “melt” from solid to liquid, and release that heat as they refreeze, maintaining a steady, comfortable temperature.
Why PCM Cooling Vests are Perfect for Costumers
For costumers, performers, and cosplayers, PCM cooling vests are the ideal solution to stay cool without compromising the look or feel of your costume.
Unlike traditional ice packs that can drop to freezing temperatures and cause discomfort, PCM packs melt and refreeze at a moderate 50-70°F (10-21°C), providing consistent cooling without becoming too cold. They are safe to wear directly against your skin, so there’s no need for any additional barriers or protective layers. And because the packs don’t produce condensation, you don’t have to worry about moisture or dampness affecting costumes.
Another key benefit is is that these vests don’t require batteries, wires, or noisy fans, making them silent and unobtrusive even on film sets or at live events. PCM packs work with your body’s natural cooling process, cooling your blood as it flows over the packs, and circulating that cooling effect throughout your body. This keeps your core temperature balanced and helps you stay focused, comfortable, and dry throughout your performance.
Integrating Cooling Vests Into Your Costume
When integrating a cooling vest into your costume, it’s essential to consider how the vest will fit and interact with your outfit. For example, a Mrs. Claus fitting for her new costume discovered that wearing UnderCool 3 added approximately one inch to her waist measurements. This extra space ensures a proper fit while accommodating the cooling vest. We recommend taking your measurements with and without wearing the cooling vest of your choice.
Our cooling solutions are versatile and can be integrated into a wide range of costume types. Whether it’s a superhero suit, period costume, elaborate cosplay or full-body mascot, ThermApparel products can be adapted to fit comfortably. The designs ensure that wearers can stay cool while maintaining the aesthetic integrity of their costumes.
Here are some considerations for making PCM cooling vests work with your costume.
Tight or Form-Fitting Costumes
For costumes that are tight or form-fitting, such as superhero suits, you may need to make small adjustments to fit the cooling vest comfortably. Adding about an inch to your measurements can help accommodate the vest. Also, consider incorporating a layer or a strategic prop to conceal the cooling packs if they are visible. In skintight costumes, cooling packs may be noticeable on your back.
Heavier Costumes
For more substantial costumes like armor, full-body suits, or historical attire, we recommend the UltraCool or RallyWrap Cooling Vests. You should plan for at least an additional two to three inches in length and depth for your pattern to ensure the vest fits comfortably without compromising the costume’s structure or appearance.
Retrofitting Existing Costumes to Include Cooling Vests
If you’re adapting an existing costume to include a cooling vest, start by evaluating whether your current attire can be adjusted. You might need to modify the fit by altering seam allowances, adding or expanding darts, or inserting a gusset or small panel to accommodate the vest comfortably.
Extra Adjustments for Enhanced Cooling
Some costumes require more than just a cooling vest to prevent overheating. Consider additional modifications that can improve airflow, such as incorporating panels or vents. Increasing airflow will significantly boost comfort. For example, adding a flap for ventilation could have provided relief for characters like Chewbacca during long takes. Similarly, installing small fans at the base of R2-D2 would have helped circulate air inside the costume. By thinking creatively about airflow, you can greatly enhance cooling and comfort.
About ThermApparel PCM Cooling Vests
ThermApparel’s PCM cooling vests fit seamlessly under costumes without adding bulk, ensuring they are discreet and photo-friendly. The low-profile design allows you to move freely and maintain the aesthetic of your costume without the cooling vest being visible or causing discomfort.
These cooling vests are lightweight and easy to recharge–taking just 30 minutes in ice water or 60 minutes in a freezer or refrigerator–and they require no electricity, cords, or fans, making them completely silent and ideal for long-lasting cooling during extended performances, events, or hot environments.
ThermApparel offers five different types of PCM cooling packs. Visit the Cooling Packs webpage for full descriptions. ExtendedCool and SlimCool, packs are articulated to move with your body, ensuring comfort and flexibility without adding bulk.
ExtendedCool: The "Workhorse" Cooling Pack
If you’re suiting up for a full day at a convention or preparing for an outdoor performance, ExtendedCool is your go-to cooling pack. It’s the “workhorse” of the group, offering 2-4 hours of cooling and versatile enough to be used with our three main products: UltraCool, RallyWrap, and UnderCool 3. It moves with your body, making it ideal for costumes that require flexibility or larger coverage. Whether you’re portraying a full-body character like Santa, a furry, or a mascot, ExtendedCool is designed to handle the heat, fitting comfor- tably under your costume and keeping you cool during long, demanding performances.
SlimCool: The "Secret Agent" Cooling Pack
For costumes that require a sleek fit, SlimCool is your secret weapon. Offering one to two hours of discreet cooling, it stays hidden beneath form-fitting outfits, ensuring you remain cool without disturbing the smooth lines of your costume. Whether you’re donning a superhero suit, or even a corseted dress, SlimCool delivers relief without sacrificing style. For those tight- fitting costumes like spandex suits or layered looks, UnderCool 3 paired with SlimCool is your go-to combination, providing cooling comfort that moves with you while staying completely out of sight.
Understanding ThermApparel's Choice of Fabrics
The fabrics used for ThermApparel cooling vest garments were well thought-out and tested. The vest easily stays in place with the athletic binding and lightweight slim straps. Because of the athletic style binding, the UltraCool and UnderCool 3 can stay up by themselves; no need to wear the straps.
All our garments use 4-way stretch Spandex because of its exceptional flexibility and comfort. They stretch both lengthwise and crosswise, allowing for a greater range of motion and a more comfortable fit, especially for close-fitting garments. This makes them ideal for ease of movement.
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Enhanced comfort and freedom of movement: Moves with your body, reducing restrictions and allowing for a more natural, flexible and comfortable experience.
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Improved fit and shape retention: It hugs the body without feeling constricting and maintains its shape even after repeated stretching and washing.
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Breathability: Offers good breathability, allowing for better airflow and moisture-wicking, keeping you cool and dry.
Our breathable mesh fabric offers several benefits to enhance comfort and performance by promoting airflow, moisture management, and quick-drying capabilities. They are especially beneficial in warm climates or during physical activities when staying cool and dry is essential.
- Superior Ventilation: The open structure of the mesh fabric allows air to circulate freely, promoting excellent ventilation and airflow. This helps to keep you cool and comfortable by allowing heat to escape easily.
- Lightweight and Comfortable: The mesh fabric is lightweight, contributing to overall comfort.
- Durability: Despite its lightweight appearance, the mesh fabric is quite durable, with interlocking or spacedout yarns providing structural integrity and resistance to wear and tear.
Breathoprene with a hook-receptive backing allows for a wide range of adjustability in sizing.
- Breathoprene: A breathable and perforated neoprene material allows air to pass through, reducing heat and moisture buildup while still providing support and compression.
- Hook Receptive Backing: A layer of looped fabric attached to one side of the breathoprene allowing it to securely fasten offering a wide range of adjustability.
Sizing for ThermApparel Cooling Vests
Getting the right size for your cooling gear is key to staying chill! Measure your natural waist—ignore the hips or pant size. Think of our cooling garments like a snug hug; they should fit closely to ensure the cooling packs make contact with your back.
If you’re between two sizes, go for the larger one to get the perfect fit. Don’t worry about your chest or cup size; it won’t affect the fit.
Check out our sizing page for more info, video and tips.
Choosing the Right ThermApparel Product
ThermApparel offers a lineup of cooling vests and wraps tailored to suit various costume types and individual preferences. Our products feature low-profile designs that fit seamlessly under your costume. They provide effective cooling without adding bulk, and they’re photo-friendly, ensuring no lumps or bumps disrupt your costume’s smooth silhouette.
Our cooling packs melt and refreeze at a comfortable 70°F (21°C), making them safe for skin contact and easy to manage throughout your day.
UltraCool 3
For maximum cooling in demanding conditions, UltraCool is your go-to solution. Designed for full-body costumes or heavy outfits worn for extended periods, UltraCool features ExtendedCool Cooling Packs that deliver superior heat management. Whether you’re performing on stage under intense lights or navigating a bustling convention, this vest provides prolonged cooling and ensures you stay focused and comfortable without any bulk.
RallyWrap
For those who need adaptable and versatile cooling, RallyWrap is the perfect choice. This flexible wrap can be worn around the waist, shoulders, or limbs, offering targeted cooling exactly where you need it. It’s ideal for costumes that require a customizable cooling solution, giving you the flexibility to stay cool whether you’re on the go or in a static position.
UnderCool 3
UnderCool 3 is a lightweight, slim cooling solution designed for discretion and comfort. Perfect for form-fitting costumes or situations where a low profile is essential, UnderCool 3 integrates seamlessly with SlimCool or ExtendedCool Cooling Packs. This cooling vest provides effective cooling without adding bulk or altering the costume silhouette, making it ideal for maintaining your appearance while staying cool.
CoolSleeve
For quick, targeted cooling, CoolSleeve is your best bet. It focuses on the radial artery in your forearm, delivering fast relief during pre and post-cooling needs. Lightweight and flexible, CoolSleeve slips easily onto your arm, offering discreet cooling that supports your performance without interfering with costume movement.
Headband
For flexible, targeted cooling around the head, the ThermApparel Headband features FlexCool dual-sided cooling packs that mold comfortably to your head, offering heat relief without compromising your costume’s fit. It’s ideal for performers needing head cooling that adapts to their movements.
Grab-N-Go
Grab-N-Go packs are your perfect solution. Offering 30 minutes of cooling relief, these packs can be easily tucked into pockets, between layers of armor, or even in your corset or sports bra. Essential for costumers who need to transition swiftly between roles or scenes, they provide immediate relief without slowing you down.
Keep a set in the freezer, ready for those unexpected moments when heat catches you off guard. Designed with performers in mind, our cooling packs work seamlessly with your costume, ensuring you stay comfortable and in character throughout your event.
Heat is a very real danger for costumers, so it is important to consider cooling when creating and wearing costumes. Our cooling solutions are designed with costumers in mind.
Integrating PCMs into our products ensures efficient heat regulation, while the lightweight and discreet design allows for comfortable wear under even the most elaborate costumes. With ThermApparel’s cooling vests and wraps, costumers can focus on delivering their best performance, without the distraction of excessive heat.
