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Open Accordion
Size + fit
Open Accordion

Fit guide: The Full Metal Jacket is designed with a loose fit, with plenty of room for other layers underneath. If you prefer a closer fit, we recommend you go for the size down.

Model wears: Runner Tyler Maher is 6ft 4 / 193cm with a 38 inch / 97cm chest. Tyler has an athletic build and is wearing the Full Metal Jacket in size XL.

Personalised advice: See our size guide for more advice on sizing, or you can ask us for personalised sizing advice here.

Returns and exchanges: Don’t worry if you order something and it doesn’t fit – we have a free, no hassle 30 day return and exchange period.

Fits chest83-9091-9899-106107-114115-122123-130
Fits waist71-7676-8181-8686-9191-9696-101
Fits chest33-3636-3939-4242-4545-4848-51
Fits waist28-3030-3232-3434-3636-3838-40
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Full Metal Jacket

The next 100 years won’t look like the last 100

As we enter a new era of disease, the Earth heats up, and fires and floods sweep across countries, we’re radically underprepared as a species for the speed at which change is taking place. As normality shifts beneath us, our survival systems need to adapt – from emergency planning and infrastructure, to our architecture and clothing. Clothes have to become intelligent, and they have to do it quickly. So we’re doubling down on our mission to design for the needs of the next century and not just the next season.

Full Metal Jacket

Why we’re looking at disease-resistant clothing

Since starting Vollebak we’ve taken the extreme questions and challenges that adventure poses and tried to solve them with pieces of clothing. One of the challenges we were already exploring when Covid-19 hit was the role clothing can play in protecting against disease in remote environments on Earth as well as up in space where astronauts’ immune systems are already compromised. While we want the first people on Mars to be wearing our clothes, making sure we survive on Earth first, and understand how to avoid taking diseases from one planet to the next, is a good starting point.

Full Metal Jacket

Why metal will be part of the future of clothing

Metal may not sound like an obvious candidate to help create the future of clothing. It’s incredibly expensive, has no real precedent in clothing beyond suits of armour, and there’s no established supply chain. But we’re exploring its potential because to make intelligent clothing you need to start with base materials that can do things normal clothing can’t. You can think of copper as a platform on top of which other innovation can be added – a bit like an operating system in a computer. Copper’s ability to resist disease, while also conducting heat and electricity without a power source, make it an obvious contender.

Full Metal Jacket

Copper will be a building block for intelligent clothing

Making clothes out of naturally conductive materials is the first stepping stone towards intelligent clothing. Over the next 10 to 10,000 years clothing has the potential to help us become stronger and faster and even live longer. But everything from exoskeletons to integrated monitoring and intelligence will require power distribution. Which is why the ability of copper and graphene to conduct heat and power while killing bacteria and viruses make them the first likely building blocks for the future of clothing. With graphene remaining incredibly expensive to produce at scale, we’re trialling copper at the same time.


Viruses and bacteria can’t live on copper

Disease resistant clothing will become a requirement in the future, which is why we’re starting to work with copper now. It’s biostatic, so bacteria and other life forms can’t grow on it. It also has exceptional antimicrobial properties which means bacteria and viruses die when they make contact with it. The copper releases electrically charged ions which first make it difficult for a microbe to breathe, before punching holes in its outer membrane, moving in and completely wiping out its DNA, preventing it from developing any future resistance. These properties have been demonstrated by an extensive body of research and have come under the spotlight again this year in initial Covid-19 studies.

Turning a theory into a jacket

So as we enter a new era of disease on Earth, and we start to think about preventing Earth’s illnesses being carried up into space, we wanted to see whether it was actually possible to make clothing almost entirely out of copper – because you can’t wear a theory. The Full Metal Jacket is our first move into copper clothing and proof of its viability. It’s built from 65% copper and has over 11 kilometres of copper in every jacket. That’s enough copper to stretch from one side of NYC to the other and back, if you got bored one day.

Full Metal Jacket

Our history of working with cutting edge materials

In our first 4 years we’ve made clothing from some of the most cutting-edge materials known to man. We built the world’s first jacket from graphene and a t shirt created entirely from plants and algae. We’ve worked with the world’s strongest fibre, Dyneema Black, as well as carbon fibre, ceramics, glass and bioluminescent material. Making the world’s most resilient, intelligent and adaptable clothing means we often end up re-engineering materials that started life being used for radically different things. And copper is the next material in our journey.

Full Metal Jacket

Copper has always been central to the history of innovation

Copper created the tools from which entire civilisations were built. It was the first metal to be cast in a mould 6,000 years ago, and the first to be alloyed to make bronze. It provided humans increasingly efficient ways to kill each other – from axes and swords to bullets. But it also gave us increasingly efficient ways to spread information – from the Gutenberg printing press, telegraph and telephone, to circuit boards, computer chips, broadband and telecommunications cables. The first clock, watch, telescope, microscope and battery all relied on copper. And if you’re reading this on your phone, 12% of that is copper too.

Full Metal Jacket

How we actually make a jacket out of metal

There’s a reason this is the first jacket to be built mostly from copper. And that’s because the process of turning metal into a wearable fabric is highly complex. The first of the jacket’s three layers is made from a lacquered copper yarn which is woven on rapier weaving looms before being scoured, heat-set, dyed and dried. This curing process alone takes six days. The lacquer is completely clear and acts as protection, so the colour of each jacket is the colour of the dyed copper beneath it.

Full Metal Jacket

What the jacket looks and feels like

The surface of the jacket looks computer generated when you’re standing in front of it. And that’s because the hundreds of thousands of moving copper parts warp and ripple like water. But while the jacket is made out of metal and looks like it’s come from another planet, you wouldn’t know it just by touching it. It’s designed to be worn as your everyday jacket and it feels like one. The copper is soft and malleable. It’s only under a microscope you can see the individual copper strands running through every jacket.

Full Metal Jacket

As the jacket ages the copper colour will come through

In order to simulate what the jacket will look like as it ages over the next decade, we attacked it with highly abrasive sandpaper and gravel. So in many of these shots you can see the raw copper colour coming through. The surface ages like denim, so lighter copper-coloured creases will gather on all points of contact and the parts of the jacket that move the most.

Full Metal Jacket

The middle layer keeps out the rain and wind

Creating a jacket from metal is even more challenging when you turn the fabric into a high-performance material as we’ve done here. The copper is laminated with an advanced waterproof and breathable membrane called c_change®. Instead of remaining static, the membrane can open and close to respond to different weather conditions as they happen, while remaining permanently waterproof and windproof. The Full Metal Jacket is waterproof to over 20,000mm and highly breathable with a RET score of 10.

Full Metal Jacket

How the membrane works in the cold

The c_change® membrane mimics natural structures like flowers and pinecones, opening and closing in response to changes in temperature, humidity and sweat. It’s designed to keep you at a consistent temperature by combining really high breathability with heat retention. While it can open up like a series of microscopic vents to let heat escape, in the cold it closes itself like a protective barrier to stop heat leaving. So as soon as the temperature drops, or you stop moving, the membrane contracts to insulate you and retain heat close to the body.

Full Metal Jacket

How the membrane works in the heat and wet

As the air temperature rises, the membrane opens up so that excess sweat and heat can escape through the jacket. But while the membrane’s polymer structure opens up to become extremely permeable to water vapour leaving the body, it remains completely waterproof on the outside. It means that even if you held a jacket under a downpour in extreme heat, the jacket will only ever let the water through one way, while still letting heat pass through it.

Full Metal Jacket

The inside is built for comfort

Once the metal face fabric and advanced membrane have been bonded together, a brushed backing is added on the inside of the jacket to make it soft. The high front collar comes with a fleece lined chinguard, and the side pockets are fleece lined too. The hood and hem both come with elasticated drawcord adjusters. The cuffs fasten tight with metal snap fasteners. And every panel of the jacket is laser cut before being stitched and bonded for waterproofness.

Full Metal Jacket

Four large layered front pockets

You’ll find two large side pockets that are lined with fleece on the inside and fasten with waterproof zippers. Two giant bellows pockets are layered over these side pockets. The bellows pockets are protected by angled storm flaps and fasten with metal snap fasteners, and each is large enough to fit an iPad or tools.

Full Metal Jacket

Three chest pockets

The jacket is fitted with a heavy-duty two-way waterproof metal front zipper. Either side of the zipper on the upper chest you’ll find two concealed pockets. Both come with waterproof zipper entrances and are hidden behind storm flaps. The two pockets are large enough for your phone. And inside the jacket there’s a third, internal pocket on the right hand side.

Full Metal Jacket

The Egyptians were using copper medical tools in 2200BC

Copper has been used to combat disease for thousands of years. The oldest medical tools ever discovered were made from copper 4,000 years ago, and were found entombed with the remains of Qar, a royal physician from the Sixth Dynasty in ancient Egypt. The Smith Papyrus shows that 1,000 years earlier the Egyptians were using copper to sterilise wounds and transport clean drinking water. And they weren’t alone. The Babylonians would sharpen their swords and put the copper alloy filings into cuts sustained in battle, to reduce infection and speed healing.


Copper’s halo effect

During the 19th century Paris was one of many cities worldwide struck by a series of devastating cholera outbreaks which killed tens of thousands of people. In 1852 a physician called Victor Burq found that the disease wasn’t killing anyone who worked in the copper smelting plants around the city. Not knowing about the ancient Egyptians, he dubbed it “the antidote to cholera.” Recent research in the US suggests that copper may produce a halo effect, potentially reducing bacteria by 70% up to 50 centimetres away from the copper itself and reducing it on surfaces not made out of copper.

Full Metal Jacket

Now it’s NASA experimenting with copper medical devices

4,000 years after the Egyptians, NASA is exploring the use of 3D-printed copper medical instruments on long-duration space missions. One of the issues with longer missions is that astronauts can experience an altered immune response, known as Immune System Dysregulation. It’s a condition that can leave them more susceptible to infectious diseases, which can harm their performance and in turn limit human space exploration. So NASA is now testing medical instruments built from copper for use onboard the International Space Station, to help reduce the risk of infection in space.

Full Metal Jacket

Copper’s future role on Mars

As Matt Damon demonstrated in The Martian, we’re going to have to be highly resourceful when we do get to Mars. Survival is going to hinge on making the most of every resource available, and Rover missions have already been able to find copper ore deposits on Mars. Even rocket parts are now being built with copper. Researchers at the Marshall Space Flight Center have recently developed and 3D-printed a new copper-based alloy known as GRCop-42. It’s incredibly strong, highly conductive and will be used to line rocket’s propulsion engines.

Full Metal Jacket

Copper is everywhere, from supernovas to your body

Astronomers believe copper was first forged inside massive stars as they grew into supergiants, and that later, when they exploded as supernovas, the copper was thrown through space to help form our planet. As well as finding copper in space, you’ll also find it as a trace element in all living organisms, including you. The average adult body contains 50-120mg of copper, which works with iron to form our red blood cells. You’ll find it mostly in our bones, muscles and liver, maintaining healthy blood vessels, nerves and immune function.

Full Metal Jacket

There’s no Tesla without copper

Copper continues to play a vital role in innovation on Earth. By 2025 the electric vehicle industry will be using over 1.7 million tonnes if the demand continues to increase. Tesla currently use 45,000 tonnes of copper every year in their cars' motors, battery and wiring, as at least 180lbs of copper goes into every electric vehicle. The increasing demand means that 90% of the world’s copper mines are now monitored by satellites. And last year Elon announced they were expecting future shortages and would consider getting into mining.

Full Metal Jacket

Copper can be recycled without any loss in quality

Copper is one of the few materials that can be recycled infinitely without losing any of its chemical properties. Recycled copper, or secondary copper as it’s known, is completely indistinguishable from primary copper, and it can be recycled from its raw state as well as from manufactured products. Copper recycling can be traced back over 2,000 years to when the Romans were recasting weapons and armour using scrap metal from foundries.

  • esquire-final

    Vollebak aims to do for outdoor clothing what Tesla did for cars and El Bulli did for food, using science, wit and imagination to create products no-one thought possible.

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