Pangaia unveils 365 Seamless Activewear, a bio-based performance collection made with EVO nylon and regen Bio Max elastane. The line offers a high-tech, fossil-free alternative in a market dominated by synthetic fibers.
In an activewear market long dominated by synthetic materials derived from fossil fuels, Pangaia is pushing forward with a collection that challenges the category from its molecular foundation. This week, the London-based materials science company will release 365 Seamless Activewear, a new performance line made entirely from renewable, plant-based fibers. This marks a major step as Pangaia becomes the first to commercially incorporate Hyosung’s regen Bio Max elastane — a stretch fiber made from 98 percent renewable resources — into an activewear collection.
The significance of this shift is not limited to brand innovation. According to Textile Exchange, synthetics like polyester and nylon account for more than 60 percent of global fiber production, with polyester alone representing 54 percent as of 2022. These fibers are almost exclusively derived from oil, contributing significantly to greenhouse gas emissions and microfiber pollution. Replacing them with bio-based alternatives, even partially, could meaningfully reduce fashion’s environmental impact.
Hyosung’s regen Bio Max elastane has been third-party tested to yield a 27 percent lower carbon footprint than traditional spandex and causes 82 percent less ozone depletion, according to verified life cycle assessments. The company made headlines in 2022 as the first to scale USDA and SGS-certified bio-based spandex using 30 percent renewable feedstocks, now adopted by brands Icebreaker, and Silver Sea Apparel, beyond Pangaia.
“Sustainable strategies vary widely among brands – whether it is recycled, bio-based or recyclable, so it’s important to provide solutions to meet their individual needs,” says Claire O’Neill, Hyosung TNC director of European brand marketing said earlier this year ahead of the brand’s appearance at Performance Days Munich.
In its recycled lineup, Hyosung integrates multi-functional properties, such as temperature regulation, odor control, and natural hand feel, into its 100 percent recycled Spandex, Nylon, and Polyester. It will also unveil regen Ocean Nylon, made from discarded fishing nets, and introduce circular polyester developed in partnership with Ambercycle, crafted from end-of-life garments.
The second key material in the collection is EVO nylon by Fulgar, a lightweight, thermoregulating yarn also derived from castor beans and industrial corn. EVO dries faster than traditional nylon and weighs less than polyester, making it ideal for athletic use. Because it is naturally non-toxic, the fabric is safe for prolonged skin contact — a critical factor for consumers prioritizing wellness alongside function. EVO is already used in technical outerwear, intimate apparel, and performance textiles, but its application in a high-performance seamless collection signals a broader shift toward bio-innovations in fashion.
Each garment in the line is finished with Pangaia’s proprietary PPRMINT, an antimicrobial treatment made with peppermint oil. The technology neutralizes odor-causing bacteria without relying on synthetic chemicals, which are commonly found in activewear to suppress sweat-induced smells. By using a plant-based treatment, Pangaia avoids conventional toxins while extending the freshness of the garments between washes — a potential water-saving benefit that aligns with the brand’s broader ecological mission.
The 365 Seamless Activewear collection launches with five foundational silhouettes in a body-hugging construction designed to sculpt and stretch with movement. The pieces come in three tonal shades, Black, Gaia Blue, and Dewy Rose, inspired by the natural elements of earth, sky, and bloom. Breathability, moisture-wicking, and next-to-skin comfort are central to the offering, with a seamless structure that avoids waste-generating cut-and-sew processes.
While most athletic wear still relies heavily on virgin polyester and traditional elastane, Pangaia’s offering is constructed entirely from plant-based, non-toxic alternatives. “By utilizing renewable, bio-based materials, Pangaia harnesses the power of nature to offer a solution that’s better for you and better for the planet,” the brand noted in a release.
Beyond material science, the seamless construction also adds a layer of environmental consideration. According to a 2023 study by the Ellen MacArthur Foundation, seamless garments reduce fabric waste by up to 30 percent compared to conventional cut-and-sew methods. Combined with the performance properties of EVO and regen Bio Max, the collection is positioned as a viable alternative to traditional activewear, without sacrificing stretch or durability.
Fulgar, the Italian textile supplier behind EVO, has increasingly prioritized R&D around sustainable fibers. It previously developed Q-Nova, a yarn made from pre-consumer industrial waste, and Q-Cycle, which uses chemical recycling to turn discarded tires into new textile fibers. Its partnership with Solvay to distribute EMANA and Amni Soul Eco across Europe and the Middle East reflects its strategy to scale regenerative yarns.
As sustainability pledges mount across the fashion sector, the bio-based performance segment remains limited. Major players like Nike and Adidas have made incremental progress in introducing recycled content and experimenting with low-impact dyes, but fossil fuel-derived synthetics still form the backbone of most collections. Analysts estimate that only about one percent of global fiber production comes from bio-based synthetics.
That makes Pangaia’s commercial rollout particularly notable. The company’s stated mission is to build an Earth-positive business model where its products are better for the planet than if they didn’t exist. While this ethos can sometimes veer into marketing abstraction, the launch of 365 Seamless Activewear represents a concrete application of those ideals through verified material innovation.
The collection will be available online and at Pangaia’s London flagship store at 57 Carnaby Street.
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