Do I need a cooling vest for my costume?

Costume Heat Risk - Are You a High-Risk, Medium-Risk, or Low-Risk Costumer?

Whether you’re gearing up for a big performance, prepping for Halloween, or just love getting into character, overheating is no fun. So, how do you know if your costume needs a cooling vest? Every costume is different, but they all come with their own “heat risks", some require extra cooling power, while others just need a little help. Are you fully covered from head to toe in layers and fur, or are you showing some skin? Understanding your risk level is the key to knowing whether you need a cooling vest.

ThermApparel Cooling Vests are the secret weapon of actors and performers in some of the hottest situations—literally! Our vests have been used on the sets 1883: A Yellowstone Origin Story, Station 19, and Nope, to name a few, helping actors stay cool under intense costumes and stage lights. You don’t need to be a Hollywood star to get in on the action! Our cooling vests are perfect for masquerades, cons, theater performances, Renaissance festivals, haunted attractions, Halloween costumes, and more.

Check your costume against our handy and funny costume heat risk guide to see if you need a cooling vest or coat with your costume.

Full Body - High-Risk Costume

• No skin in sight
• Covered in fake fur
• Wearing a full headpiece or mask
• Gloves, boots—the whole shebang
• Loves communicating in gestures and staying anonymous

Do they need a cooling vest?

Oh, absolutely. No coat required here! You’ll want to stay cool under all that. We recommend the UltraCool or RallyWrap and CoolSleeves to keep you comfy and safe.

Layered - High-Risk Costume

• Rocking 3+ layers (cape, coat, hat, gloves—you name it)
• Pants, leggings, maybe even a wig or beard
• Built this look piece by piece, every detail counts
• Fully committed to the character

Do they need a cooling vest?

Absolutely! You’ve crafted this look with care, and every detail matters. Stay cool and keep your hard work flawless with the UltraCool or RallyWrap and CoolSleeves for a fast, targeted cool down.

Layered -  Medium-Risk Costume

• 3 layers or more, but showing some skin
• Hats, sandals, lighter fabrics
• Easy to slip on/off
• Great for last-minute party appearances or quick gigs

Do they need a cooling vest?

Yes! We suggest UnderCool 3 for comfort without the bulk and CoolSleeves for a fast, targeted cool down.

Revealing-  Low-Risk Costume

• Lots of skin, minimal fabric
• Practically looks like underwear
• No pockets for your phone
• Definitely not something for Grandma’s Sunday dinner

Do they need a cooling vest?

Nope, they need a coat!

 

Want to learn more about ThermApparel Cooling Vests and specific costume, performance or acting needs? Check out these pages. 

Santa
Furry Fandom
Haunt performers
Theater and Movie Actors and Performers
Costumers
Cosplay
LARP
Renaissance Festival Performers

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You might have seen a ThermApparel Cooling Vest in action and didn't even know it! 

Did you know many movies, TV shows, and theater productions with fall and winter scenes are filmed in July and August in 90˚F+ heat in Atlanta, California, and Florida?

Yup! Can you imagine wearing a winter coat and boots in the middle of summer? Actors, cosplayers, furries, and performers often need cooling because of their costumes, like the actors in authentic firefighting gear on Station 19.

Actors, furries, cosplayers, haunt performers, and theater performers have used ThermApparel Cooling Vests in these exact situations. We’ve helped keep performers cool in:

Nope, Utopia, DMZ, Gossip Girl, Waltons, Station 19, Santa at the mall, cosplay conventions, furry cons, haunted houses actors, Renaissance Festivals, and theater productions.

But you don’t have to be a big-time star to benefit from a ThermApparel Cooling Vest. Get one for your Halloween costume, haunt event, community theater production, college theater, high school mascot, cosplay, furry costume, LARP, or Renaissance Festival.

Have questions about bulk orders for your performers, cast, or team? Give us a call: 855-232-7233.

 

What sizes do ThermApparel Cooling Vests come in?

Our vests are designed for a wide range of body types so your costume stays comfortable and your cooling packs stay in place:

• UnderCool 3: XXS, Small, Medium, Large, XXL — adds about 1 inch to your back.

• RallyWrap: Size 6 and 8 — adds about 1 inch to your front and back.

• UltraCool: M/L and XL/XXL — adds about 1 inch to your front and back.

Check out our cooling vest size chart, fitting instructions for all sizing details, and a helpful video showing how to get the perfect fit.

Sizing tips:

• Measure your natural waist, not your hips or pants size.

• Vests should fit like a glove for maximum cooling support.

• If you fall between sizes, order the larger size.

• Need help? Call 855-232-7233 — we’re happy to guide you.

How do I order a ThermApparel Cooling Vest?

Ordering is simple:

1. Visit our Cooling Vest Shop.

2. Select your size and preferred cooling pack type.

3. Enter your shipping and payment information.

4. We’ll ship your vest directly to you!

Need help? Call 855-232-7233 — we’re happy to take phone orders.

How do ThermApparel Cooling Vests keep me cool under my costume?

ThermApparel uses Phase Change Material (PCM) packs, not ice or gel. PCM works with your body, not against it.

Why it matters:

• Ice or gel packs: Too cold, constrict blood vessels, limit circulation — great for injuries, not full-body cooling.
  
  

• PCM packs: Safe, skin-friendly (~70°F / 21°C), allow blood to flow freely. Cool blood circulates throughout your body, lowering your core temperature.

Result: Even, lasting cooling under your costume — no drips, no frostbite risk, no bulky ice packs. Perfect for Santa, furry, haunt performers, cosplay, LARP, Renaissance Festival, or theater performers.

Will a ThermApparel Cooling Vest be comfortable while seated?

Absolutely! Designed to move with you, whether you’re sitting, standing, performing, or dancing. Many performers forget they’re even wearing it!

Santa, furries, cosplayers, and haunt performers rely on ThermApparel vests to stay cool during long cons, haunt events, or hot mall appearances, focusing on the fun instead of the heat.

ThermApparel vests keep you cool and dry during:

• Long conventions or furry cons

• Hot mall appearances

• Theater performances or Renaissance Festivals

• Cosplay events or LARP battle

• Hot stuffy haunted houses

No bulky ice packs, no sweat-soaked discomfort — just reliable comfort that works with your body.

Can I dance in a ThermApparel Cooling Vest?

Yes! Dance, shimmy, or shake your groove thang — ThermApparel vests move with you. Designed for maximum mobility, they stay in place while keeping you cool on stage, at a convention, or in costume.

 

Will it interfere with my costume fit?

Because the cooling packs sit low on the back for UnderCool 3 and in the front and back fro RallyWrap and UltraCool and the vest is low-profile, it won’t drastically change the size you normally wear.

• UnderCool 3 adds about 1 inch to your back.

• RallyWrap and UltraCool add about 1 inch all the way around your torso.

If your costume is not skin tight, it should still fit comfortably. The vest stays hidden under your outfit, letting you stay cool without compromising your look.

 

Will anyone know I’m wearing it?

Unless you’re in something super skin-tight, no one will notice.

• UnderCool 3: Velcro closure in front, low-profile back design

• RallyWrap & UltraCool: Sleek front and back packs, discreet under costumes 

How long will it keep me cool?

Cooling times depend on vest and pack type:

• UnderCool 3 with SlimCool Packs: 1–2 hours

• UnderCool 3 with ExtendedCool Packs: 2–3 hours

• RallyWrap with ExtendedCool Packs: 3-4  hours

• UltraCool with ExtendedCool Packs: - 3-4 hours

Need longer? Swap or refreeze packs for continuous cooling. You can even double up packs, though this adds a bit more weight.

Refreeze times:

• Ice water: 30 min

• Freezer: 45 min

• Fridge: 60 min

Keep your extra Cooling Packs in an insulated cooler, and they’ll stay cold for hours. For even more convenience, store them in ice water so you can refreeze spent packs on the go.