Breaking the mold of dual-density wetsuits

The original ISURUS wetsuits, born out of the challenging waters of Mavericks, embody a pioneering spirit that remains at the core of our brand DNA today. The same demanding conditions that inspired those early surfers to conquer such formidable waves continue to drive our innovation and commitment to excellence.

We have a long history of pioneering innovation within the surfing wetsuit industry, and that's no different when it comes to aspects of wetsuits that are sometimes taken for granted.

The truth is that surfing is an insular sport that adapts slowly, but that will not stop ISURUS from challenging the status quo.

This article is a deep dive into why ISURUS is taking on the long-accepted notion of dual-density wetsuit thicknesses.

Read on for a brief history to understand why wetsuits are normally built in this way (i.e. 3/2 and 4/3) and why this is not benefitting surfers. (Hint: you're being sold two wetsuits when you could be buying one that's better quality!)

Why single density?

ISURUS has opted for single-density wetsuits in the Shield Series instead of traditional dual-density wetsuits because we can, and because it makes sense.

Let us explain.

When discussing "dual density" wetsuits, we refer to the traditional 3/2mm, 4/3mm, etc. configuration, in which the core body of the suit is thicker than the arms and legs.

To understand the background of our decision to adopt this strategy, it's essential to know why dual-density wetsuits were ever a "thing" in the first place and how material technology has developed and enabled us to change the way we look at wetsuit design and functionality.

A Brief History of Dual-Density Wetsuits.

The history of dual-density surfing wetsuits traces back to the evolution of wetsuit technology designed to balance warmth, flexibility, and durability for surfers. Here's a brief breakdown of how wetsuits have developed over the decades:

1950's - 60's: Early Wetsuits

● Origins: Neoprene is a material invented by DuPont in the 1930’s. Wetsuits as garments for warmth were first developed in the 1950s by physicist Hugh Bradner and later commercialized in 1952 by Jack O'Neill in San Francisco and, shortly after, the Meistrell brothers (founders of Body Glove Wetsuits) in the South Bay.

● Material: Wetsuits were made from neoprene (an advanced material for aircraft/aerospace and refrigeration insulation). When adapted for use in the first surfing wetsuits, neoprene provided insulation by protecting from the elements and trapping a thin layer of water, which was kept relatively warm by heat generated by the body.

● Challenges: Early surfing wetsuits were bulky and stiff but proved a huge benefit, enabling people to survive and thrive longer in the cold waters of San Francisco, Santa Cruz and other cool to cold climates.

1970's – 80's: Advances in Material Science

● Breakthroughs: With surfing gaining popularity and spreading worldwide, manufacturers like O'Neill, Body Glove, and Rip Curl experimented with lighter, more flexible neoprene.

● First Use of Dual-Density Foam: In the early 80s, Rip Curl is largely credited with the first wetsuits engineered with different densities (thicknesses) for example; in specific areas—thicker foam in the chest and back was used for warmth and thinner, more flexible foam in the arms, gussets, and legs for mobility. This evolution had a considerable impact when surfing became a global sport and was pursued in climates far from the warm beaches of Hawaii and other warm climates.

1990's – Early 2000's: Modern Dual-Density Designs

● Zipperless arrives on the scene: The first commercially viable Zipperless wetsuit was introduced into the market by Billabong in 1998. Invented by designer Mark Machado (now with ISURUS), industrial designer Brad Bissell and others, it was originally patented by Billabong USA’s parent company. This design changed the game and ushered in a new century of wetsuit design and innovation.

● Technical Integration: Companies introduced advanced dual-density wetsuits with advancements in neoprene technologies, specialized linings, surface treatments, and a whole host of new features and benefits that were used for savvy marketing and sales strategies, designed to entice customers, and differentiate from the many new brands diving into the wetsuit market as the surfing industry exploded in size, globally.

● Commercial Benefits: These wetsuit companies also used dual-density for cost-saving - with a portion of the wetsuit being a thinner material, it's possible to save money on the arms and legs. In many climates, you now need a 3/2mm for Spring / Fall and a 4/3mm for winter - so you can sell two wetsuits that are slightly different and require two suits for climate variations rather than provide a higher quality single-density wetsuit that will see you through.

2010s-present: Innovation in Dual-Density Wetsuits

● Thermal Linings: Internal linings, like quick-dry jerseys, far-infrared and graphene-infused fibers, promised improved insulation but failed to deliver on that promise and fade from the scene as quickly as they come in.

● Material Innovation: Brands like Patagonia, Finisterre, Vissla, and others have embraced “sustainable” materials such as Yulex and other natural additives claiming to be better for the environment, but these materials are often less stable and inconsistent in performance characteristics.

ISURUS - Built Different:

We prefer to lead the pack than follow it, and a couple of factors allow us to adopt a different approach from the rest of the industry; the fact we are independently-owned, and our commitment to real design innovation.

We would rather sell you one genuinely great wetsuit that will set you up to surf through many seasons than many poorly made wetsuits full of marketing gimmicks that are destined to fail. 

ISURUS Materials.

At ISURUS, we have opted for Yamamoto's Limestone Neoprene, which has proven to be far more UV/salt/chemical resistant and far more stable creating a higher performing, more durable and long lasting material than natural rubber (a combination of plant based rubber and synthetic EPDM), allowing our wetsuits to last many seasons of use while others break down and need replacing much more often.

Our high-end, innovative materials allow us to break out of the confines of conformity and offer best-in-class wetsuits.

ISURUS uses two compounds of Yamamoto limestone-based neoprene in our wetsuits, which allows us to offer Single-Density suits, especially in our ZipFree Shield Collection.

ISURUS Shield Series uses a mix of materials (Japanese limestone neoprene and nylon jerseys) of the same thickness -

#40: Has more stretch and recovery but less compression. It retains elasticity and recovery, providing a better fit. Used for the ZipFree entry and gusset panels.

#39: Is lighter and offers better compression characteristics. It is used in the rest of the suit for better muscle stabilization and compression – enhancing warmth, blood circulation, and muscle recovery.

We also use premium (Oeko-Tex certified) jerseys that provide additional functionality, compression, stretch, durability, and warmth compared to cheaper options, while maintaining a high quality standard in environmental and human health safety.

By combining high-quality Yamamoto single-density (thickness) materials in an intelligently designed and rigorously tested wetsuit, you get the best of both worlds: warmth comparable to a regular 4.3 wetsuit but more flexibility than a mass-market 3.2 wetsuit—basically, one wetsuit takes the place of three dual density suits without sacrificing any warmth or performance characteristics associated with multi-density products using lesser-quality neoprene.

The Shield ZipFree design not only eliminates the traditional chest zip but also all the seams and paneling needed to hold the zip in place. This results in almost 'zero restriction' when paddling in the ZipFree. And if you're paddling more, you naturally stay warmer! The design provides a better range of motion and less resistance, which helps you retain energy when needed.

The ZipFree provides a better range of motion and less resistance, which helps you retain energy when needed.

ISURUS Durability

With ISURUS, you're not just buying a wetsuit for the season. You're investing in a companion that will see you through Fall to Spring and many more years of surfing adventures. Our wetsuits are built to last, providing you with the confidence and reassurance you need to focus on your performance in the water.

At ISURUS, we view sustainability and value through a different lens. As an independent company, we prioritize selling you a single wetsuit that not only performs better and lasts longer but also aligns with your environmental values. We believe in creating products that go the distance, rather than relying on seasonal gimmicks that prompt you to replace your worn-out, albeit slightly cheaper, wetsuits.

Our brand of "sustainability," if you will, is built on quality materials, exceptional performance, longer life span/durability, and consciously sourced materials and manufacturing channels—Sustainability at its best. We believe in buying better instead of chasing fickle trends and fad marketing spin.

ISURUS - Not for everyone

Sure, there are still times when a dual (or even triple) density wetsuit makes sense, but with our single-density 3mm wetsuits being comparable in thermal properties to a 4.3 and the flexibility of a 3.2, multi-density is only really needed for very cold conditions, when dual-density wetsuits actually start to make sense.

ISURUS wetsuits are not for everyone, but if you've read this far, they're the right choice. Our customer promise is that we'll provide balanced information and personal support throughout your experience with ISURUS.

Are you ready to become a maverick and break with the pack for a modern approach to wetsuit design?