Chronic exposures to toxic combustion products found in the fireground environment are believed to contribute significantly to the higher rates of cancers experienced by firefighters. When used during fire suppression and overhaul stages, the self-contained breathing apparatus (SCBA) protects the highly susceptible respiratory tract from the toxicants in smoke and soot. However, firefighters are still being exposed to hazardous particulates when smoke penetrates the interfaces in the turnout ensemble and deposits on the firefighter's skin. There is an identified need for improved interfaces of structural firefighter personal protective equipment (PPE) that will reduce the risk of skin absorption of harmful toxicants and carcinogens. The newly developed smoke-resistant turnout provides vulnerable interfaces in the PPE with enhanced protection from exposure to smoke and other fireground contaminants. The smoke-resistant turnout implements smart interface designs and novel materials in key areas for the turnout coat while retaining thermal comfort and thermal protection compared to existing turnout gear. Protection against smoke and particulates was evaluated through standardized aerosol testing at the system level and has further demonstrated the material and design effectiveness of targeted areas for increased protection. This newly developed system could seamlessly be used to replace existing gear as well, as both donning and doffing protocols remain virtually identical.