How to Design the Thickness of Wetsuit?

There are many people who would like to do the wetsuit business, but they don’t really know the technology of wetsuit, this is not so good for achieving their business, customize wetsuit style would be important when we would like to build the wetsuit brand, but the thickness of wetsuit is also important, otherwise, if the wetsuit can not meet your target market, the project would fail. 

Designing the thickness of a wetsuit is a careful balancing act between warmth (insulation) and flexibility / mobility. The core principle is simple: thicker neoprene provides more warmth but is less flexible.

Here is a detailed breakdown of how to design and select the appropriate thickness for a wetsuit in this article. If you would like to know more, welcome to Wetop Sports knowledge center.

The Fundamental Principle How Thickness Provides Warmth

Wetsuits work by trapping a thin layer of water between your skin and the suit. Your body heats this water, and the neoprene (the foam rubber material) acts as an insulator, slowing down the loss of that heat to the colder surrounding water. Thicker neoprene provides a greater barrier against heat loss.

Key Factors to Consider When Designing Thickness

When deciding on thickness, you must evaluate these factors:

Water Temperature: This is the most critical factor.

User Activity Level: A surfer sitting on a board will get colder faster than a swimmer constantly moving.

User Personal Physiology: Some people naturally feel the cold more than others.

Zoning (Differential Thickness): This is the hallmark of a well-designed wetsuit.

Step-by-Step Design Guide

STEP 1: DETERMINE THE CORE THICKNESS BASED ON WATER TEMPERATURE

Use the water temperature as your starting point. Here is a general guideline:

Note on the "mm" notation (e.g., 3/2 mm): This indicates differential thickness. The first number is the thickness on the torso and core (where you lose the most heat), and the second number is the thickness on the arms and legs (where you need more flexibility).

STEP 2: APPLY "ZONING" OR DIFFERENTIAL THICKNESS

A wetsuit with a single uniform thickness is inefficient. A smart design places thicker material where it's needed most and thinner material where flexibility is crucial.

Thicker Panels (for Warmth):

Torso / Chest / Back: The core body, where your vital organs are located. Keeping this area warm is the top priority.

Upper Thighs / Kidneys: Areas prone to heat loss.

Thinner Panels (for Flexibility):

Shoulders / Underarms: Critical for arm movement in swimming, paddling, and surfing. Thinner material here reduces fatigue.

Back of Knees / Inside Elbows: Allows for a full range of motion without constriction.

Example of a Zoned Design: A 4/3 mm suit has 4 mm neoprene on the torso and 3 mm on the arms and legs. A high-end suit might even have 5 mm on the lower back and 2 mm under the arms.

STEP 3: REFINE BASED ON ACTIVITY AND PHYSIOLOGY

High-Activity (Swimming, Triathlon): Prioritize flexibility. A triathlete in 65°F (18°C) water might choose a sleeveless 2mm or a very flexible 3/2 mm suit to allow for a freestyle stroke, whereas a surfer might prefer a 4/3 mm for the extra warmth during periods of inactivity.

Low-Activity (Scuba Diving, Snorkeling): Prioritize warmth. A scuba diver, who moves less and cannot easily surface, will choose a thicker suit, perhaps a 5 mm or even 7 mm for colder water.

Cold-Natured Individuals: If you know you get cold easily, consider a suit that is one step thicker than the temperature chart suggests.

Other Critical Factors Beyond Thickness

The thickness of the neoprene is just one part of the equation. The quality of the neoprene is equally important:

NEOPRENE TYPE:

Standard Neoprene: Heavier, less flexible, and absorbs more water.

Super-Stretch / High-Grade Neoprene: Much more flexible, lighter, and provides better warmth for its thickness. This allows a 3 mm high-end suit to be as warm as a 4 mm standard suit while offering superior mobility.

Limestone Neoprene: A more eco-friendly option that is often softer and more flexible.

SEAMS:

Flatlock Stitching: Suitable for warm water. The seams are not fully waterproof.

Glued Blind Stitching (GBS): The panels are glued together and then stitched from the inside. This prevents water from flushing through the stitch holes, greatly improving warmth.

Liquid Taped Seams (Sealed): The internal seams are sealed with a liquid rubber tape, making the suit almost completely watertight. This is the warmest and most advanced seam construction.

LININGS:

Nylon Linings: Standard.

Fleece / Lined Panels: Some suits have a plush, fleece-like lining on the torso panel for added warmth and comfort.

Summary: The Design Process

Start with Water Temperature: Use the chart as a baseline.

Define the User & Activity: Adjust the baseline thickness up (for less activity / cold-natured users) or down (for high activity / warm-natured users).

Design the Zoning Map: Decide on the differential thickness pattern (e.g., 4/3 mm, 5/4/3 mm) to maximize core warmth while preserving mobility in key areas.

Select Neoprene and Construction Quality: Choose high-stretch neoprene and sealed seams for colder water or higher performance needs. This can sometimes allow you to use a slightly thinner suit without sacrificing warmth.

By following this process, you can systematically design or select a wetsuit with the perfect thickness for your specific needs.

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