This research has designed and prepared a protective clothing layer by integrating porous silica aerogel with nonwoven fabrics for simultaneous chemical and thermal protection. Protective interlining having resistance to heat and liquid chemical penetration was developed by sandwiching randomly distributed aerogel particles between viscose nonwoven fabric layers. The nonwoven layer and aerogel particle layer were explored by analysing fabric surface morphology. Physical characterization of the test specimens revealed that the weight and thickness of fabric increased after the integration of aerogel particles. Consequently, improved chemical resistance and thermal resistance were observed in the aerogel-nonwoven fabrics with higher aerogel concentration. For clothing comfort, the high air permeability indicated sufficient breathability by transferring air and water vapour from the body to the atmosphere and vice versa through apparel. Improved evaporative transmittance and cooling index of aerogel-fabrics suggested that the fabric will create a favourable thermal comfort microenvironment between the skin and apparel. For wear comfort regarding wet clinginess, the high water uptake and evaporation rate of the fabric specimens indicated their ability to retain and evaporate large amounts of perspiration vapour in a hot and humid atmosphere. The overall performance of the aerogel-nonwoven fabrics suggested that the integration of silica aerogel with viscose nonwoven fabric is a prospective approach for developing protective interlining that will provide reliable chemical and thermal protection as well as adequate clothing comfort to the wearer.