Five wearable jackets engineered to hold real pickles and brine for a KFC campaign.

Nexform was tasked with designing and building five custom “pickle puffer” jackets for a high-profile global campaign for KFC, supporting the launch of their new pickle range across the UK. The project was developed under a tight two-week turnaround ahead of a scheduled photoshoot in Shoreditch with KFC. The core challenge was to engineer a wearable, sealed garment capable of safely containing real pickles and pickle brine without leakage, while still maintaining a structured, wearable jacket form suitable for photography and broadcast. With only two weeks on the clock, the team had to solve a genuinely unusual engineering problem and still produce a finished garment that looked the part on camera.

The development process involved initial design and structural concept development for fluid containment garments, followed by extensive testing of multiple flexible materials for waterproof and puncture resistance. Early prototyping began with PVC sheeting, before transitioning to polyethylene-based sheeting due to improved durability and sealing performance. A key part of the solution was the development of sealed internal compartments using a 1m heat sealing system, alongside the design and 3D printing of custom valve components to allow controlled filling of each unit. Throughout development, iterative testing was carried out to resolve issues relating to leakage, pressure stability and puncture resistance. Each round of testing fed directly into the next, gradually refining the materials, seals and valves until the jackets could hold their contents reliably while still wearing like a proper garment.

Despite multiple technical challenges during prototyping and testing, Nexform successfully delivered five final production units within the required timeframe for the Shoreditch photoshoot. The campaign later gained significant international exposure, featuring across media including “Have I Got News For You” Heart radio in the UK and CNN in the United States, contributing to a viral global response. What started as a tightly scoped UK launch reached audiences well beyond it. This project highlights Nexform’s capability in rapid experimental prototyping, unconventional material engineering, and delivering complex creative engineering solutions under strict deadlines for major global brand campaigns.