Origins In 1952,
UC Berkeley and subsequent
UC San Diego SIO physicist Hugh Bradner, who is considered to be the original inventor After experimenting with the material and finding it superior to other insulating foams, O'Neill founded the successful wetsuit manufacturing company called
''O'Neill'' in a San Francisco garage in 1952, later relocating to Santa Cruz, California To mitigate this issue, divers resorted to generously applying
talc powder to both the suit and their body to facilitate smoother sliding of the rubber material. Backing materials first arrived in the form of nylon knit cloth applied to one side of the neoprene. This allowed a swimmer to pull on the suit relatively easily since the nylon took most of the stress of pulling on the suit, and there was less friction between the nylon and skin, but the suit still had the bare foam exposed on the outside and the nylon was relatively stiff, limiting flexibility. A small strip of neoprene reversed with the rubber against the skin could help provide a sealing surface to keep water out around the neck, wrists, and ankles. In 1960, the British Dunlop Sports Company brought out its yellow Aquafort neoprene wetsuit, whose high visibility was intended to improve diver safety. With this technology, the suit could be sewn and then taped, and the tape would cover the sewing holes as well as providing some extra strength to prevent tearing along the needle holes. When colorful double-backed designer suits started appearing, taping moved primarily to the inside of the suit because the tape was usually very wide, jagged, black, and ugly, and was hidden within the suit and out of sight. Many 1960s and 1970s wetsuits were black with visible yellow seam taping. The yellow made the divers more easily seen in dark low-visibility water. To prevent needle holes from leaking, O'Neill fabricators developed a seam-tape which combined a thin nylon layer with a polyester hemming tape. Applied over the interior of the glued & sewn seam, then
anneal bonded with a hand held teflon heating iron produced a seam that was both securely sealed and much stronger.
Seam gluing Another alternative to sewing was to glue the edges of the suit together. This created a smooth, flat surface that did not necessarily need taping, but, raw foam glued to foam is not a strong bond and still prone to tearing. Most early wetsuits were fabricated completely by hand, which could lead to sizing errors in the cutting of the foam sheeting. If the cut edges did not align correctly or the gluing was not done well, there might still be water leakage along the seam. Initially, suits could be found as being sewn only, glued only, taped only, then also sewn and taped, or glued and taped, or perhaps all three.
Blindstitching Sometime after nylon-backed neoprene appeared, the
blind stitch method was developed. A blindstitch sewing machine uses a curved needle, which does not go all the way through the neoprene but just shallowly dips in behind the fabric backing, crosses the glue line, and emerges from the surface on the same side of the neoprene. This is similar to the
overlock stitching used for teeshirts and other garments made from knitted fabrics. The curved needle allows the fabric backing to be sewn together without punching a hole completely through the neoprene, and thereby eliminating the water-leakage holes along the seam. Blindstitch seams also lay flat, butting up the edge of one sheet against another, allowing the material to lay flatter and closer to the skin. For these reasons blindstitching rapidly became the primary method of sewing wetsuits together, with other stitching methods now used mainly for
decorative or
stylistic purposes.
Further advances in suit design Highly
elastic fabrics such as
spandex (also known as lycra) have mostly replaced plain nylon backing, since the nylon knit fabric cannot be stretched as much as when elasticised with lycra fibres. Incorporating lycra into the backing permits a larger amount of stretching that does not damage the suit, and allowed suits to be stretched more to fit while remaining acceptably comfortable, making the tailoring less critical. After the development of double-backed neoprene, singled-backed neoprene still has its uses. A narrow edge strip of smooth surfaced single-backed neoprene wrapped around the leg, neck, and wrist openings of the suit creates a more effective seal against the skin than the knit fabric backing, that reduces the flushing of water in and out of the suit at these places as the person moves. Since the strip is narrow, it does not drag on the skin of the wearer much and the lining makes the suit easy to put on and remove. The strip can also be fitted with the smooth side out and folded under to form a seal with a small length of smooth surface against the skin and slightly greater contact pressure. This type of seal can also be used on neoprene dry suits as it is sufficiently watertight when properly designed. In the early 1970s
Gul Wetsuits pioneered the one-piece wetsuit named the 'steamer' because of the visible condensed water vapour given off from the suit when taken off, allowing heat and water held inside to escape. One-piece wetsuits are still sometimes referred to as 'steamers'. Precision
computer-controlled cutting and assembly methods, such as
water-jet cutting, have allowed ever greater levels of seam precision, permitting designers to use many small individual strips of different colors while still keeping the suit free of bulging and ripples from improper cutting and misaligned sewing. Further innovations in CAD (Computer Aided Design) technology allow precision cutting for custom-fit wetsuits.
Return of single-backed neoprene As wetsuits continued to evolve, their use was explored in other sports such as open-water swimming and
triathlons. Although double-backed neoprene is strong, the cloth surface is relatively rough and creates a large amount of
drag in the water, slowing down the swimmer. A single-backed suit has a
smoother exterior surface which causes less drag. With the advances of elastic Lycra backings and blindstitching, single-backed neoprene suits could be made that outperformed the early versions from the 1970s. Other developments in single-backed wetsuits include the suits designed for
free-diving and
spearfishing. Single lined neoprene is more flexible than double lined. To achieve flexibility and low bulk for a given warmth of suit, they are unlined inside, and the slightly porous raw surface of the neoprene adheres closely to the skin and reduces flushing of the suit. The lined outer surface may be printed with
camouflage patterns for spearfishing and is more resistant to damage while in use. Some triathlon wetsuits go further, and use rubber-molding and texturing methods to roughen up the surface of the suit on the forearms, to increase drag and help pull the swimmer forwards through the water. Extremely thin 1 mm neoprene is also often used in the under-arm area, to decrease stretch resistance and reduce strain on the swimmer when they extend their arms out over their head. Wetsuits used for
caving are often single-backed with a textured surface known as "sharkskin" which is a thin layer where the neoprene is less expanded. This makes it more
abrasion resistant for squeezing between rocks and doesn't get torn in the way that fabric does. Another reason to eliminate the external textile backing is to reduce water retention which can increase
evaporative cooling and
wind chill in suits used mainly out of the water. ==Types==