Flightsuits & Coveralls
Shop one-piece flight suits and coveralls that cover you from collar to ankle in a single garment, with no gap at the waist for cold air or dirt to get in.
The Rothco Flightsuit is the centerpiece. It follows the military aviator layout: a two-way front zipper, zippered pockets on the chest, sleeve and legs, adjustable waist tabs, hook-and-loop wrist cuffs, leg zippers for pulling it on over boots, reinforced shoulders and underarm vents. It's made of a cotton/polyester blend and comes in sizes from XS to 8XL in olive drab, foliage green, black, navy, khaki, orange and woodland camo.
For cold work, Rothco Insulated Coveralls pair a 65/35 poly/cotton twill shell with 6 oz. poly fiberfill, knit wrist cuffs, a two-way front zipper and zippered legs. The Rothco Workwear Coverall covers the same ground for shop and job-site use, and the Ski and Rescue Suit is built for snow.
Kids get their own section: a Kids Flightsuit, an olive drab flight coverall with patches, kids' insulated coveralls and NASA flight coveralls with an official NASA patch, which make a popular costume and a practical play suit.
A note for service members: these are commercial garments, not issue aircrew uniforms. The Rothco Flightsuit is cotton/poly and isn't sold as flame resistant, so it's not a substitute for an issue flight suit in an aircraft. It's best for airsoft, costumes, events and work. Details below.
How to Choose Flight Suits and Coveralls
Start with what the suit has to do: look the part, keep you clean, or keep you warm.
Flight Suits for Airsoft, Costumes and Events
A one-piece flight suit is the base for any aviator outfit. The Rothco Flightsuit has the pocket layout people expect, with zippered storage on the chest, arm and legs, so add patches and a name tape and the look is complete. It's also comfortable enough for a full day at an airsoft game or a car show, thanks to the underarm vents and adjustable waist.
Coveralls for Work
Coveralls protect your clothes from grease, paint and dirt. The workwear coverall is the year-round choice, while insulated coveralls add fiberfill for winter jobs, hunting blinds, ice fishing and outdoor shifts where you stand still for hours. The ski and rescue suit is the pick for snow sports and winter rescue drills.
Kids' Flight Suits and Coveralls
The kids' flightsuit and NASA flight coveralls are favorites for school projects, space camp, dress-up and Halloween, and the kids' insulated coveralls handle sledding and farm chores.
Sizing Flight Suits and Coveralls
One-piece garments need more length through the torso than a shirt and pants. If you're tall or long in the body, size up so the suit doesn't pull at the crotch or shoulders when you bend or reach overhead. Use the adjustable waist tabs to take in extra room. For insulated coveralls, size for the layers you'll wear underneath, and use the leg zippers to get them on over boots.
Military Flight Suits and Aircrew Uniform Rules
Real military flight suits are protective equipment. The current U.S. issue flight suit is the CWU-27/P, made of Nomex, a flame-resistant aramid fabric, in sage green or desert tan. Every pocket sits on the front, arms or legs so aircrew can reach it while seated.
Army Aircrew Uniform
For the Army, DA PAM 670-1, paragraph 6-1, describes the Army Aircrew Combat Uniform (A2CU) in OCP as the daily work, utility and field uniform for aircrew members. The same paragraph describes the Fire Resistant Environmental Ensemble (FREE) as a modular, flame-protective layer worn with the prescribed duty uniform. Who may wear these uniforms, and when, is set by regulation and by the aviation unit.
Where Our Flightsuit Fits
The Rothco Flightsuit is a commercial cotton/poly garment that isn't sold as flame resistant. It isn't an issue item and shouldn't be worn as aircrew protective clothing or as part of a uniform. Use it for training props, events, unit morale functions where your command allows it, airsoft and costumes. If you fly, wear the flight suit your unit issues and follow its policies, which can be stricter than the regulation.
Adding Patches and Finishing the Look
Flight suits are made to be personalized. Sew-on or hook-and-loop patches, a leather name tag and a squadron-style patch on the shoulder turn a plain suit into a convincing aviator outfit. Browse our patches and insignia to finish it.
Caring for Coveralls
Close all zippers before washing so the teeth don't snag other fabric, and wash insulated coveralls on a gentle cycle so the fiberfill stays evenly spread. Follow each garment's care label.