The Gore-Tex Saga: Gen 2

Based on feedback from soldiers, Marines and Airmen, the Second Generation (Gen II) ECWCS was developed in the late 1990s, and was revolutionary in terms of design. Three of the items used in the previous system - the M65 liner and trousers, the polyester fiberpile shirt and overalls, and the snow camouflage parka - were excluded from the new system. Natick Labs decided to instead work on a more simple system that would not take up as much space in the user’s closet, lighten their load and provide optimal protection from the elements for prolonged periods of time. An insulating soft polyester fabric known as polar fleece - patented and owned by the outdoor company Polartec - would catch the Army’s attention. Polartec would end up being a major contributor to the development of the Gen II, and created a synthetic fleece shirt and overalls as one of the new items. This new system was designed to be lighter, more durable and with better insulation and breathability to protect against the elements. As modern warfare evolved and the US began operations in Iraq and Afghanistan, the new focus was on moving quickly and accomplishing the mission as fast as possible. Gen 2 was initially issued to the Marines, and in the 2000s, it would also end up being adopted by the Army. Gen 2 ECWCS was released in the early to mid-1990s as a replacement for the older Gen 1, but would only remain in use for a decade until the Army and Marines replaced it with their Gen 3 and APECS systems respectively. 

LAYER 1

The first layer was the Lightweight Cold Weather Underwear Set (LWCWUS). The undershirt and the drawers are composed of 100 percent polyester material which weighs no less than 4.2 ounces per square yard and no more than 5.5 ounces per square yard. The undershirt has long sleeves with elastic wrist cuffs, which consist of double thickness of the basic fabric. The wrist cuffs have sufficient elasticity to prevent constriction of blood flow to the hands. The undershirt has a zipper that begins in the center of the collar top and extends to a level near the bottom of the user's chest, designed for easy operation with a gloved hand, and provides the user with ventilation during strenuous activity. The drawers extend from the user's waist to a level below his/her ankles and end with elastic ankle cuffs. The ankle cuffs consist of double thickness of the basic material. The ankle cuffs have sufficient elasticity to prevent constriction of the blood flow to the feet. The waist band is made of an elastic hydrophobic, synthetic material. The drawers have a standard fly hole in the front.

LAYER 2

The second layer consisted of the Synthetic Fleece Shirt and Overalls, replacing the Gen 1’s  polyester fiberpile shirt and bib overalls. The shirt has a center front opening with a two way slide fastener closure backed by a wind protection flap. It also has a collar, raglan sleeves with underarm slide fastener openings and a wrist tab with hook and loop adjustments, two internal upper chest pockets, two lower hand warmer pockets with slide fastener openings lined with ThermaStat or equal, and nylon reinforcements at the upper back, shoulders, upper chest and elbows. Nylon/lycra binding is used on the edges of the wind flap and bottoms of the sleeves, and the shirt bottom is faced with a nylon binding that covers an elastic cord and has cord lock adjustments at each side seam. All slide fasteners have a thong for ease of opening when wearing gloves. The overalls are of the bib type, with adjustable suspenders, side full-length slide fastener closure, and center front slide fastener fly opening. All slide fasteners have a thong for ease of opening when wearing gloves. This design provides a garment that is light in weight, low in bulk, has environmental protection, and comfort in movement.

LAYER 3

The third and final layer was the Cold / Wet Weather Parka and Trousers. Some of the Gen 1 Gore-Tex parkas experienced problems with leaking, necessitating the development of a new one that was more waterproof by design and the parka was improved by vents to help deal with the condensation problems resulting from the use of "breathable" fabric. Initially, the Parka and Trousers were made in Woodland camouflage, but in the mid-2000s, the Army switched over to the three-color digital Universal Camouflage Pattern (UCP). The parka has two side access hand warming pockets, two cargo pockets, two side access breast pockets, two upper sleeve pockets, a moisture - wicking barrier at the waist and sleeve cuffs, extended drop tail and a roll and stow hood that fits into the collar as well as water shedding slide fasteners and zippered armpit vents. The ultralight, three - layer breathable Gore-Tex barrier protects against water and wind, and is softer and quieter than the first generation design. It also allows sweat to escape without sacrificing protection from the elements. The parka is also designed with an optional hood which attaches to the parka collar by hook and pile tape and interfaces with the fur ruff, a component of the ECWCS. The trousers are camouflage to the outside with an elastic drawcord at the waist, slide fastener fly opening and ankle openings with fastener tape adjustment tabs. They have sealed Gore-Tex seams, a reinforced seat and knee with high-strength nylon fabric and zippered leg openings, secured by velcro with moisture-wicking barriers. There are a total of four pockets, the cargo pockets with velcro closures and two pass-through front pockets.