When CMI2 identified thermal protective materials capable of resisting rope burn, the challenge became making those materials wearable — without compromising dexterity, comfort, or longevity. I was brought in to lead soft goods prototyping and pattern development for a glove that could shield Soldiers during rope descents without interfering with critical hand function.

​

The design required multiple layers of a specialized heat-dissipating foam, along with rope-facing leather for durability. However, conventional seam techniques would have made the glove far too bulky to allow for finger articulation. I developed an innovative seam construction method that allowed for multi-layer protection without building up stiffness at the joints. I also used gussets, knit inserts, and material hybrids to counterbalance the rigidity of the leather and preserve tactile feedback.

​

To increase glove durability, I carefully layered and enclosed the foam with woven fabrics, webbing, and leather tape, resolving early fraying issues and extending the usable life of the prototypes. Once the design was validated, I graded the patterns across size ranges and created comprehensive build documentation to ensure consistency in future production.