How Neoprene Wetsuits Are Made — The Complete Manufacturing Process

Introduction

Wetsuits have become essential equipment for diving, surfing, triathlon, and water sports. But how exactly are they made? Here is a step-by-step breakdown of the full manufacturing workflow used by modern factories.

1. Material Selection

Wetsuit performance depends on the neoprene quality:

• CR Neoprene for premium wetsuits

• CR/SBR blended foam for mid-range wetsuits

Foam is laminated with:

• Nylon

• Lycra

• Polyester

• Sharkskin (embossed neoprene)

2. Pattern Design

Each wetsuit has multiple panels designed for:

• Flexibility (arms, shoulders)

• Warmth (chest, back)

• Durability (knees, elbows)

High-end suits use 3D body mapping to improve fit.

3. Cutting

Computer-controlled cutters ensure accuracy, reducing material waste and improving efficiency.

4. Gluing & Blind Stitching

Premium wetsuits use:

• GBS

• Spot taping

• Liquid Seal

5. Assembly

Panels are glued, stitched, bounded, and reinforced at high-stress points.

6. Testing

Each wetsuit must pass:

• Stretch test

• Water-resistance test

• Seam durability test

• Thermal insulation test

7. Branding & Customization

Options include:

• Screen print logos

• Silicone heat transfer

• Embossed rubber patches

• Custom zipper pulls

Conclusion

Manufacturing a wetsuit is a complex process combining material science, garment engineering, and precision craftsmanship. Understanding these steps helps brands evaluate quality and choose the right factory for OEM/ODM production.