Next-generation pilot suits are evolving into intelligent, adaptive platforms that integrate advanced polymeric materials, smart textiles, and on-body artificial intelligence. High-performance polymers have advanced in mechanical strength, thermal regulation, and environmental resilience, with fabrication methods like electrospinning, weaving, and 3D/4D printing enabling structural versatility and sensor integration. In particular, functional nanomaterials and hierarchical nanostructures contribute critical properties such as conductivity, flexibility, and responsiveness, forming the foundation for miniaturized sensing and integrated electronics. The integration of flexible fiber-based electronics such as biosensors, strain sensors, and energy systems enables real-time monitoring of physiological and environmental conditions. Coupled with on-body AI for multimodal data processing, autonomous decision-making, and adaptive feedback, these systems enhance pilot safety while reducing cognitive load during flight. This review places a special focus on system-level integration, where polymers and nanomaterials serve as both structural and functional components in wearable technologies. By highlighting the role of nanostructured and functional materials within intelligent textiles, we underline a potential shift toward active human–machine interfaces in aerospace applications. Future trends and advancements in self-healing materials, neuromorphic computing, and dynamic textile systems will further elevate the capabilities of intelligent pilot suits. This review discusses interdisciplinary strategies for developing pilot wearables capable of responding to real-time physiological and operational needs.