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Wetsuits Technology

materials: neoprene

Features

Raw material:
Wetsuits are usually made of a synthetic, closed cell rubber foam called neoprene. The raw materials (rubber, carbon powder and other chemical components from DuPont) are mixed and “rise” like dough in flat bowls with a size of 2 × 1 meters.

Sheets:
These neoprene sheets are then sliced into thinner sheets of the required mm thickness with band knife machines.

k_type neoprene

This shock absorbing neoprene type is used for the ION crash_padz to reach a maximum of protection in stress areas.

n_type neoprene

This premium neoprene type is even softer and provides more stretch than the S_Type_Neoprene. It’s our most elastic neoprene in the range and is used for double lined panels such as collar, arms, shoulder and armpit area when most extreme elasticity is needed.

s_type neoprene

ION wetsuits are all made of S_Type_Neoprene which is one of the most elastic neoprene type on the market. It’s also very warm and lightweight due to its specific cell structure.

materials: jersey

Features

Single lined:
neoprene wetsuits commonly have a jersey lining laminated on the inside for more convenience when putting on and taking off the suit, as well as to enhance wearing comfort and thermal insulation on
the naked skin.

Double lined:
a second jersey lining is often applied to provide abrasion resistance and add some color and design options to the black neoprene skin.

Wind-chill-effect:
due to the wind-chill-effect a single lined skin wetsuit will always be warmer for kite- or windsurfing compared to a double lined wetsuit, as the neoprene skin dries quicker.

Jersey choice:
there are different types of jersey that vary in elasticity, insulation, wearing comfort, abrasion resistance, UV protection, color fastness and of course price.

Glued Blindstich

Application:
This seam technology is most commonly used for thicker wetsuits from approx. 3 – 6 mm thick
Neoprene which require best waterresistance.

Glueing:
The edges of the Neoprene panels are covered with a highly adhesive, UV resistant contact glue
which needs to dry for a few minutes. Then the glue is applied a second time to make it more sticky.

Assembling:
Now the corresponding edges of the Neoprene panels are put together by hand and then firmly
squeezed with an electric pressing tool cm by cm to achieve the high tearing strength.

Sewing:
After glueing, the seams are stitched on one side with a special blind-stitch sewing machine.
A curved needle pokes through the neoprene layer (without actually poking through the Neoprene
to the other side) and applies an elastic seam. If you can see the stitching only on one side of the
seam then it is a glued bind-stitch seam.

Pros:
By using this technique, the seam is highly tear proof, elastic and very much waterresistant to
provide insulation and comfort.

Cons:
This manufacturing process is extremely complex and timeconsuming, and therefore very expensive.

Gate_Keeper

Problem: when you put on a wetsuit with batwing construction
just by yourself, the Water_Gate back panel tends to roll up
inside and makes it hard to grab it without help.

Solution: A Velcro patch on the upper part of the batwing
makes it possible to fix the batwing on the neck closure. This
prevents the Water_Gate back panel from rolling up inside and
helps you grabbing it without the help of an assisting buddy.
The Gate_Keeper Velcro patches on the batwing and neck
closure are indicated in red color, so you can easily see how to
close it.

Tatex_Protectors

Highly abrasion resistant protection printings on the knee panels. Flex zones allow outstanding freedom of movement

Contour_Cut

In order to improve mobility and comfort, all ION wetsuits come with a contour cut. It enhances the flexibility in the collar, wrist, ellbow, instep and the hollow of the knee.

Crash_Padz

Additional neoprene pads which protect sensitive body areas like the shins, ribs, crotch, hips, tail bone, etc. against pressure and impact injuries when crashing hard. Each Crash_Padz consists of a specialized higher density K_Type Neoprene foam to absorb the impact force.

Slip_Loop

All Rashguards, Thermo Tops and Neoprene Tops have a fine webbing loop on the center of the hem for fixing the boardshorts laces to prevent slipping up by impact.

UV_Protection

All ION Rashguards, Thermo Tops and Neoprene Tops are made of extaordinary soft quality Jersey and Neoprene to provide maximum protection against the aggressive UV radiation of the sun (UPF rating 35 to 50+ depending on the color).

Chest_Logo

on each ion wetsuit the logo is printed on the left chest side.

Seam_Reinforcements

All crucial stress points are reinforced either with Melco_Tape on the inside seams or rubber logo patches on the outside to prevent ripping.

Water_Gate_Plus

All ION semidry wetsuits with long arms / long legs are equipped with a Water_Gate_Plus batwing panel on the inside of the back behind the zipper. It works like a water barrier to keep out the water which soaks through the back zipper. To improve the waterproofness even more, all ION batwings (except Capture) have an additional cuff extension like a collar worn over the head. On top of that the glued blind-stitched seam is covered with an extra Neoprene tape sealing to keep you dry and warm on the inside.

gecko_grip

Ever watched a gecko running up and down the walls? Then you know inspiration for our new Neo Glove palm construction: A very thin layer of Neoprene with a full cover palm embossing in circular ribbed shape provides awesome grip on the wet surface of a boom or kite bar. It prevents cramps and makes a huge difference compared to conventional glove constructions.

p_zip

The ultimate answer to a full bladder in a drysuit when it’s f***** freezing outside … This unrestricting TIZIP Master_Seal zipper (same quality as on the back) provides the crucial feature for a long day on the water. The easy pull zipper tap can be stored hidden inside the opening above so noone will even notice it´s there.

panda_paw

A unique rubber patch construction on the new Neo Socks which provides both abrasion resistance and protection as well as grip and pure barfoot feeling.

tatex_glue

Additional layer of Tatex_Glue applied on GBL seams (e.g. Neo gloves and Neo socks) makes them highly waterproof and tearing resistant. A highly complex process which is only applied to the most premium products.

supra_tex

Highly abrasion resistant protection fabric used for knee panels or in the
buttock for example.

glide_skin

A soft PU coating applied onto the Neoprene to make the surface smooth and slick.
For example used on inside layer of collar to avoid rash and improve water sealing.

D_Fence Nylon

Durable and resistant Nylon jersey with great price-performance ratio. (Indicated by Grey color inside Jersey)

Cyber_Stretch

Extemely elastic and soft touch jersey with high content of Spandex filaments. Best choice for all areas with maximum freedom of movement like arms, shoulder, armpits, upper body, etc.

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