Design of thermal suits for industrial workers working in hot, stressed conditions was a six-month product design exercise undertaken by me under the guidance of Prof. GG RAY, IDC IIT Bombay. The objective essentially was to use the vortex tube technology and use its specific advantages to create a product that is economically viable and more user-friendly than existing technologies. The project was sponsored by ESSEN ENGINEERS, MUMBAI. The sponsors initially provided us with technological logistics along with a vortex tube and a suit. Henceforth, it was left to us to integrate the technology into a user-friendly product designed specifically for the target users. The product, which was eventually prototyped, is the result abstract of a planned design process involving inputs from human physiology, fabrics, pneumatics, fashion, and thermodynamics, to name some of them. Special care was taken to keep in mind the capabilities of sponsors in actually manufacturing the suit in desired numbers. The suit has to compete with other imported concepts only in terms of cost, which was illegitimately high for their poor product packaging. The cost of the suit has been kept optimum in terms of its utility and economics. The design is dedicated to Indian industrial workers who work in extremely pathetic conditions for meagre financial benefits. Their extremely poor working conditions created the passion and urgency in the design process, which helped me to reach this stage. Although the design will help them in more than one way, more still needs to be done at the system level, where the administration takes measures to educate their workers on industrial safety.