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AI Meets PPE: Fire-Dex Unleashes Virtual Sizer

The First Tool to Measure Firefighters in MINUTES

Fire-Dex, a global leader in PPE for first responders, understands that performance, safety and comfort all start with gear that fits correctly. That’s why the company is excited to launch the Virtual Sizer, a first-of-its-kind tool for the fire services that revolutionizes how firefighters get measured for their turnout gear.

Fire-Dex’s Virtual Sizer saves time and ensures firefighters receive gear tailored precisely to their measurements, minimizing safety risks from improper fit, such as exposed skin or restricted movement. The Virtual Sizer brings science to sizing using AI-driven algorithms and simple questions (like height, weight and shoe size) to accurately capture measurements in minutes without ever pulling out a tape measure.

“We’ve already seen more than 6,500 entries,” said Todd Herring, VP of Product Innovation and Strategy at Fire-Dex. “The response has been incredible. Firefighters are getting gear that fits better, faster. We’ve actually been testing and refining this technology internally for over five years to ensure accuracy before making it widely available. The human touch still matters, but the Virtual Sizer can back it up with data-driven precision to help nail the fit every time.”

No Sizing Gear or Measuring Tapes

The Virtual Sizer has already demonstrated its effectiveness in real-world use. Tested by firefighters from departments across the country, it consistently delivers results comparable to traditional sizing methods.

But the goal isn’t just to match human accuracy—it’s to improve upon it. The traditional sizing process inherently involves variations and inconsistencies due to differences in judgment, measurement techniques, and human error. The Virtual Sizer was designed to eliminate those inconsistencies, which leads to better fitting PPE.

“The technology is backed by over 150 million AI-generated digital twins and validated through extensive firefighter-specific data,” said Herring. “It’s precise, tested and constantly improving with every use—meaning the more firefighters use it, the smarter and more accurate it becomes.”

Sizing in Memphis

For the City of Memphis Fire Department, the Virtual Sizer proved to be a game-changer for onboarding new recruits, and particularly those coming from out of town.

“One of our biggest challenges has been sizing firefighters from out of town, from areas where we’ve built strong recruiting partnerships,” said Keith James, Division Chief of Logistical Services. “It can be difficult for them to fly or drive in just for processing and fittings, especially when we’re trying to get gear ordered quickly so it arrives during class.”

The department began using the Virtual Sizer specifically for these remote recruits, enabling accurate sizing without the usual time, travel and logistical hurdles. As James shared, the experience exceeded expectations.

“We tested it first with a few people locally and found the output matched our sizing. That gave us the comfort level to roll it out further,” he explained while noting how the tool was ultimately used to size 25-30 out of state recruits. “Everything turned out well, and we didn’t need to rework or resize anything. It was very easy to implement.”

For Memphis Fire, the Virtual Sizer is a solution that saves time, cuts costs and enhances the department’s ability to recruit from a wider geographic pool.

“Our AI tool streamlines ordering, but the real winners here are the firefighters,” Herring said. “The process is faster, but more importantly, emergency responders end up with gear that fits well and lets them focus on the job. It’s another example of how Fire-Dex continues to innovate and apply new technologies to serving those who serve.”

To learn more about the Virtual Sizer and how to use it, visit Find Your Fit or contact your dealer representative.