From Innovation to Ignition: The Rise of Rayon 

When rayon was first introduced in the early 20th century, it was hailed as a marvel of modern manufacturing - the first synthetic fiber, often marketed as “artificial silk.” Developed from regenerated cellulose, rayon was soft, lustrous, and far cheaper than silk, making it wildly popular in the 1930s and 1940s. The fashion industry embraced it, and consumers, unaware of its dangers, wrapped themselves and their children in the sleek, affordable material. 

But beneath its glossy surface, rayon harbored a hidden danger. Unlike natural fibers such as wool, which tends to smolder, rayon ignites quickly and burns fiercely. By the mid-20th century, reports began to emerge of devastating fires - particularly involving children’s sleepwear. In homes where smoking was common and matches or open flames were part of daily life, rayon garments became deadly hazards.  

The Tragedy that Sparked Change 

The 1940s saw a wave of clothing fires linked to rayon, many of them fatal. Stories of children whose nightclothes caught fire circulated widely, shocking the public and prompting policymakers to act. According to Emily Oster, “Back in the 1940s, a lot of clothes were made of rayon, including children’s clothing. Rayon is highly flammable, and there were tragic deaths of children whose clothing caught fire and could not be extinguished.” 

This was more than a consumer issue — it was a wake-up call about hazard communication. The very label “inflammable” on rayon garments contributed to the confusion. Many consumers interpreted “inflammable” as “cannot catch fire,” when, in fact, it means the opposite: highly flammable. This tragic misunderstanding underscored a fundamental gap in public comprehension of safety language and labeling — one that occupational health and safety (OHS) professionals still work to close today. 

The Flammable Fabrics Act: A Turning Point 

The crisis culminated in the Flammable Fabrics Act of 1953, passed in the United States and influencing similar standards internationally. The Act sought to regulate the manufacture and sale of dangerously flammable clothing, particularly for children. It required manufacturers to use materials that met specific flammability standards or treat fabrics with flame-retardant chemicals. 

However, these chemical treatments carried their own risks. Subsequent research linked some flame retardants to health concerns, including cancer. By 1996, regulations were amended to allow untreated fabrics as long as they met two conditions: the garments had to be snug-fitting and clearly labeled as flammable. As Emily Oster continues to explain in her article “Why Are So Many Baby Clothes Flammable?”, this snug-fitting rule helped reduce the chance that loose fabric would catch fire, and the updated labeling aimed to inform consumers without misleading them. 

This evolution from miscommunication to informed labeling represents a broader shift in safety culture - one where clear hazard communication became a moral and regulatory imperative. 

The Labeling Revolution: Lessons for OHS and Product Safety 

The rayon tragedies of the 1940s illuminated a core truth: safety labels are only effective if they are understood. The word “inflammable” serves as a linguistic cautionary tale - proof that even accurate labels can fail when they aren’t clear to their audience or average consumer. 

For OHS managers and product safety professionals, the rayon story reinforced the importance of plain-language hazard communication. In workplaces, the same principle applies: a “flammable” warning on a chemical drum or work uniform means little if workers misinterpret it. Modern safety standards, including WHMIS and OSHA’s Hazard Communication Standard, were built on the realization that misunderstanding a label can be just as dangerous as ignoring one. 

The rayon crisis thus helped accelerate the move toward standardized, globally recognized hazard symbols and terminology, ensuring that the meaning of a label doesn’t get lost in translation, literally or figuratively.  

From Factories to Families: Fire Safety Awareness Expands 

The lessons learned from rayon’s hazards rippled far beyond textile factories and regulatory offices. Fire prevention campaigns of the 1960s and 1970s increasingly targeted both workers and consumers, teaching people to “Stop, Drop, and Roll” and to recognize flammable household materials. 

Modern fire safety guides like the EMSA’s “Fire Safety Tips: Fire Hazards and Clothing” echo these lessons: 

“Consider the flammability of certain fabrics containing cotton, cotton/polyester blends, rayon, and acrylic. These are relatively easy to ignite and burn rapidly.” 

Today, consumers are urged to consider fabric content when buying clothing, especially sleepwear and loose-fitting garments. The idea that the fiber itself can pose a hazard is now embedded in both consumer education and occupational safety programs.  

A Canadian Perspective: Regulation and Public Awareness 

The Government of Canada’s 1981 report on consumer attitudes toward flame-retardant sleepwear showed that awareness was improving but uneven. Many parents expressed confusion about labeling and chemical treatments, reflecting the same challenges that plagued rayon’s early history. 

Over time, Canadian regulations, such as the Hazardous Products (Children’s Sleepwear) Regulations, have continued to evolve, balancing flammability protection with health concerns from chemical treatments. The report highlighted how public education - combined with clear labeling - was essential in building trust and understanding among consumers. 

This evolution in consumer policy paralleled changes in OHS practices across industries: hazards once considered “technical” or “scientific” became part of everyday awareness campaigns. Workers and parents alike began to see safety not as a burden, but as a shared responsibility.  

Rayon’s Legacy: A Catalyst for Clarity and Care 

The story of rayon is more than an episode in textile history - it’s a case study in how tragedy can drive cultural change. From the introduction of fire-resistant standards to the shift toward plain-language labeling, the lessons learned from rayon’s hazards have saved countless lives, both on the job and at home. 

Today, thanks to these lessons: 

• Workplace uniforms must meet strict flammability standards. 
• Consumer labeling is designed to be unambiguous, often supported by international pictograms. 
• OHS training emphasizes the importance of understanding safety data sheets (SDS) and product labels, not just reading them. 

In short, the painful past of rayon helped forge a future where communication and comprehension are just as important as compliance. 

The Fabric That Wove a Safer Future 

Rayon’s legacy is twofold: it represents both the dangers of technological progress without adequate foresight and the capacity of society to learn from those dangers. The confusion over “inflammable” may seem almost quaint today, but it stands as a timeless reminder that clarity saves lives. 

From the homes of 1940s America to the construction sites of modern Canada, the evolution of labeling, standards, and safety education all trace their lineage back to the lessons learned from a fabric that burned too easily - and from a world that learned, sometimes painfully, what true fire safety means.