How Wetsuits Are Made
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Wetsuits are engineered to trap body heat and protect against cold water, and their production blends science and craftsmanship. The process starts with neoprene, the core material—a synthetic rubber foam infused with nitrogen gas bubbles, which insulates by reducing heat transfer.
First, neoprene sheets are cut to precise patterns using computer-aided design (CAD) to ensure a snug fit. Thickness varies (from 2mm to 10mm+) based on water temperature needs. Next, layers are bonded: high-quality suits use glued-and-blind-stitched (GBS) seams, where panels are glued then stitched without piercing all layers, minimizing water entry.
Reinforcements are added for durability—knees, elbows, and high-wear areas get extra neoprene or nylon patches. For specialized suits (like spearfishing or surfing), features such as drainage zippers, hoods, or padding are integrated. Finally, the suit is sealed, tested for leaks, and trimmed for comfort.
Every step balances flexibility, insulation, and strength, turning raw neoprene into a vital barrier between divers and the elements.
