Flame Manikin System for Protective Clothing Testing – QualiFlame™ FMS
Full-Body Thermal Exposure Simulation for Burn Injury Prediction
Flame Manikin System is an advanced testing platform designed to evaluate the thermal protection performance of fire-resistant garments under controlled flash fire conditions. Fully compliant with ISO 13506 and ASTM F1930, this system uses an instrumented life-sized manikin equipped with high-speed sensors to measure and predict body burn injury when exposed to real flame environments.
Ideal for certifying firefighting gear, industrial flame-resistant clothing, and military PPE, the Flame Manikin System provides essential data for ensuring user safety and regulatory compliance in high-risk workplaces.
QualiFlame™ FMS is designed to evaluate the performance of protective garments exposed to short-duration flash fire conditions. This system uses a life-sized manikin to accurately, consistently, and rapidly simulate heat transfer between the human body, clothing, and the surrounding environment during a flash fire.
In the test, the manikin is placed in a controlled fire setting where heat flux, flame exposure, and burn duration are precisely regulated. The system predicts the location and severity of second- and third-degree burns on the body, providing a clear assessment of the garment’s overall thermal protection capabilities.
The Flame Manikin System is fully compliant with ASTM F1930 and ISO 13506 standards.
 Flame Test Manikin Schematic |  Flame Test Manikin Chamber |
Flame Test Manikin consists of:
- Flame Test Manikin used in the QualiFlame™ FMS is an original U.S.-designed unit, with body dimensions conforming to ASTM D6240 standards. Its construction features a fire-resistant ceramic composite for maximum durability under extreme conditions.
- The manikin is engineered to withstand high temperatures and is used in bare body calibration tests at a flame intensity of 84 kW/m², exposed to open flame for a minimum of 12 seconds.
- The manikin's surface is divided into 124 defined zones, each equipped with a highly responsive copper calorimeter heat sensor for accurate thermal measurement.
- High-temperature resistant metal support tubes are integrated into the manikin's neck, routing the sensor cables securely to the embedded heat sensors.
- Each copper calorimeter sensor delivers precise, fast-response readings across a measurement range of 0 to 167 kW/m², ensuring accurate data capture during testing.
- The system includes a calibration module for both sensor accuracy and positional alignment.
- A 12-torch array, made up of cast iron burners, surrounds the manikin to deliver a uniform heat flux of at least 84 kW/m². Each burner features an individual gas distributor, adjustment handle, needle valve, and flame protection mechanism to prevent backfire.
- The burners can be operated individually or in groups, offering consistent and controlled flame output. Each burner is equipped with its own ignition system and flow control, enabling instant flame generation via remote activation.
- Propane is supplied through multiple cylinders connected to a manifold, regulated by a precision pressure control system to ensure consistent gas flow and stable flame conditions.
- The modular burn chamber measures approximately 4 meters in height, 5 meters in length, and 5 meters in width—larger than the minimum specified by ASTM F1930—providing enhanced testing performance.
- Safety features include a built-in gas leak detection system that automatically shuts off the propane supply if a leak is detected.
- The chamber is equipped with a large, high-temperature resistant glass observation window for real-time test monitoring and recording.
- A forced-air ventilation system quickly removes smoke and residual heat after each test cycle, restoring fresh air for the next operation.
- The system’s data acquisition unit captures readings from all 124 sensors simultaneously, with each sensor recording at a minimum rate of 10 samples per second.
- Included software supports real-time sensor monitoring, calibration routines, standard testing workflows, and automated calculation of results, including burn severity and affected area, with options for exporting comprehensive test reports.
Flame Test Manikin Software
ASTM F1930, ISO 13506 Test Procedure
01 Instrumented Manikin  | 02 Dressed Manikin  | 03 Manikin Test  | 04 After Test  |
Qualites offers a complete turnkey solution for Flame Test Manikin systems compliant with ISO 13506 or ASTM F1930. The package includes the burn chamber, test manikin, control system, ventilation system, and operating software.
Applications
- Certification and R&D testing of firefighting suits
- Evaluation of industrial flame-resistant garments (FR clothing)
- Military and tactical protective gear validation
- PPE development for oil & gas, utilities, and emergency response
System Components (Typical Setup)
- Life-size, articulated manikin with 100+ embedded thermocouples or heat flux sensors
- Flash fire test chamber with controlled ignition system
- Gas control unit and burner array
- Data acquisition and analysis software
- Burn injury prediction module (based on Stoll or HTP models)
- PC workstation with intuitive control interface
Why Choose This Flame Manikin System?
Backed by precision engineering and advanced thermal modeling software, this Flame Manikin System offers the most realistic, repeatable, and standards-compliant platform for burn injury prediction in protective clothing testing. Whether for R&D, compliance, or production QA, this system ensures confidence in your garment’s real-world performance.
Protect lives. Prove performance. Test with ISO 13506 / ASTM F1930 compliant Flame Manikin Systems.
