Scientists have developed a new spray that slows how quickly cotton fabrics ignite, giving vital extra seconds in fire emergencies. The transparent coating preserves the softness and breathability of textiles while delaying ignition and significantly reducing heat release. Researchers at the University of New South Wales have found that the breakthrough could offer everyday fire safety protection for clothing, bedding, and household fabrics.
- Treated cotton took twice as long to ignite under direct flame exposure compared to untreated material during laboratory fire tests.
- The protective layer reduced peak heat release by nearly 90 per cent, cutting maximum heat output to just 11 per cent of untreated fabric.
- Simulated fire environments showed skin-side fabric temperatures remained below 40°C even when external exposure reached 100°C.
- The study, developed by UNSW’s ARC Research Hub for Fire Resilience Infrastructure, Assets and Safety Advancements, was announced last week.
INSIDE THE LAB: Researchers at UNSW spent two years developing a water-based spray that coats cotton with an invisible layer of protection. The project was funded by the Australian government via a $5m grant through the ARC Research Hub for Fire Resilience Infrastructure, Assets and Safety Advancements. The innovation follows earlier work on fire-retardant paints, extending the team’s expertise to everyday textiles.
- The formula uses phosphorous and nitrogen compounds combined with a water-soluble cellulose extract derived from plants.
- Cotton was chosen due to its widespread use in clothing, bedding, and other household materials globally.
- The formulation maintains neutral pH and caused no observed skin irritation during preliminary low-dose testing.
- The coating is non-toxic, dries instantly, and does not affect colour, softness, or breathability of the treated fabric.
WHY IT MATTERS: For communities exposed to bushfires and accidental burns, ordinary clothing and bedding represent a hidden vulnerability. Untreated cotton burns rapidly, offering little chance to react in emergencies. By delaying ignition and reducing heat intensity, the spray could provide households with an affordable and practical protective layer, potentially lowering injury risks in fire-prone environments.
- Treated fabrics limited surface heat transfer to 30–40 per cent of external temperatures.
- Protection prevented scalding by keeping skin-side fabric temperatures under 40°C in simulated fires.
- The coating survives light water exposure but dissolves completely after a rigorous wash, restoring normal flammability.
- Researchers caution that the spray provides supplementary safety only, not complete immunity against fire.
PROOF IN THE TESTING: Laboratory trials compared identical cotton fabrics, one treated and one untreated, under direct flame. The differences highlighted measurable safety benefits. Treated samples resisted ignition longer, produced less heat, and charred instead of fully combusting. Researchers measured peak heat release rate reductions of nearly 89 per cent, proving the coating’s effectiveness in slowing fire growth.
- Treated cotton required twice the exposure time to ignite under flame testing conditions.
- The maximum heat output from treated fabric reached only 11 per cent of the untreated sample’s heat release.
- Lower peak heat release rates slow fire spread and limit damage intensity, buying critical escape time.
- Charred treated fabrics retained integrity, whereas untreated cotton disintegrated into flames within seconds.
ON THE HORIZON: UNSW researchers are working with AI solutions partner N2N AI to prepare the spray for commercial rollout within a year. Before release, dermatological tests and further trials on polyester and other textiles will continue. The team emphasises that while the spray is not a fireproof shield, its protective layer may offer valuable seconds to escape during emergencies.
- Formulation stability ensures shelf life exceeding one year when bottles are sealed against oxidation.
- The spray can be applied directly onto fabrics, but protection disappears once it undergoes a rigorous wash.
- Researchers stress the spray adds only a layer of defence, not full fireproofing, similar to applying sunscreen.
- Future product iterations may target synthetic textiles, with polyester trials already showing promising results.
WHAT THEY SAID:
It’s an added layer of protection, not a magical force field. If someone is alone, it might be tricky to spray their back – just like applying sunscreen. And we’re not saying this will make people completely fireproof but it can slow down the rate of your clothes burning – and potentially reduce injury in a fire. That delay could be crucial in emergencies, offering precious seconds to escape.
— Guan Yeoh
Director, ARC Research Hub for FRIASA
University of New South Wales
