No matter how much they exercise or how carefully they watch what they eat, Army helicopter pilots have a weight problem.

They strap on an average 40 pounds of protective and survival vests when they squeeze into their cockpits, and the load can go up to 100 pounds if they are flying over water and need chemical suits, too.

All of this gear is bulky, making it hard to move and very hard to get out of the helicopter fast in an emergency, and it is hot and uncomfortable. The armor plates in protective vests can cut into thighs, sometimes causing numbness.

The latest in "wearable technology" should provide some relief, as Betsy Dart will explain at a conference that begins today at the David L. Lawrence Convention Center, sponsored by the Industrial Fabrics Association International.

Based in Roseville, Minn., the association represents more than 2,000 manufacturers of specialty fabrics, and the Pittsburgh expo will feature safety and protective fabrics, as well as medical textiles.

Dart, who grew up in Wexford, is a textile engineer for Computer Sciences Corp., a defense contractor. She's based in Huntsville, Ala., where she's been working on the "Air Warrior" program, the first military ensemble that incorporates not just what pilots wear and carry, but the harnesses in their aircraft, as well.

"Helicopter pilots have special requirements," she said. "If you don't have it on your body, you are going to get out of the aircraft without the equipment you need. They were frustrated by the survival vest that led to constricted cockpit mobility'' and limited their ability to exit in an emergency.''

The flak vest was redesigned, using soft armor and ceramic plates, which increased ballistic protection while reducing weight. Reconfiguring the armor placement put an end to numb thighs, while providing improved protection for vital areas.

An internal pocket system and a redistribution of survival gear (pistol, radio, beacon, compass, etc.) reduced torso bulk. Equipment was placed where it was easy to retrieve but least likely to interfere with access to flight controls.

Especially welcome for helicopter pilots flying in Iraq in the summer is the addition of a micro-climate cooling vest, which runs on aircraft power.

The new ensemble weighs about a third less than the vests and harnesses it will replace, but costs about the same -- around $500 a set, Dart said.