Outdoor gear giant Patagonia has introduced a pioneering circular solution for wetsuits in collaboration with Bolder Industries, transforming old Yulex wetsuits into new, eco-friendly surf and dive gear.
Patagonia, a leader in environmentally responsible surf gear, has announced what it says is a revolutionary circular solution for wetsuits, developed in collaboration with Bolder Industries. Patagonia began collecting old Yulex wetsuits, made from natural rubber, earlier this year. Bolder Industries breaks down these suits at the molecular level to produce carbon black, which is used in the dyeing process for new Yulex wetsuits. Carbon black is crucial for coloring the recycled nylon lining of the wetsuits, making up about 15 to 20 percent of the rubber foam in Patagonia’s wetsuits. The production process of Bolder Industries’ carbon black, known as BolderBlack, reduces water use by more than 90 percent and reduces greenhouse gases by more than 90 percent compared to traditional methods.
“We hope that this breakthrough in recycling and circularity will go well beyond the surf industry and will eventually be implemented across countless product sectors,” Hub Hubbard, Patagonia’s Surf Product Line Manager, said in a statement. “Yes, other brands have offered wetsuit collections for recycling, but the wetsuits have so far only been broken down mechanically into things like yoga mats and playground material. We are constantly working to reduce our impact and share solutions within the industry. Currently, we are collaborating with multiple brands to convert their wetsuits to Yulex and implement this program with Bolder Industries, providing a sustainable end-of-life solution.”
Neoprene-free wetsuits
Patagonia began its journey toward eco-friendly wetsuits in 2008 by partnering with Yulex to create a bio-based rubber alternative to neoprene. This innovative material, derived from hevea tree sap instead of crude oil or limestone, led to the release of the first neoprene-free wetsuit in 2012. By 2014, Patagonia shared this breakthrough with the entire wetsuit industry.
The larger adoption of Yulex by major wetsuit brands has been “amazing,” says Jason McCaffrey, Patagonia’s Director of Surf. “This end-of-life solution through our partnership with Bolder Industries is just one more benefit of using natural rubber.”
In 2020, Patagonia established the Wetsuit Forge, a dedicated research, development, and repair center. This facility allowed the company to streamline design and repair processes, resulting in the updated 2023 Yulex Regulator wetsuits, which are more flexible, easier to repair, and come with a lifetime warranty. The wetsuits now also have a sustainable end-of-life solution. At the Wetsuit Forge, Patagonia collects old wetsuits, removes the zippers, and sends them to Bolder Industries, where carbon black is extracted. This reclaimed material is then sent to Patagonia’s manufacturer, Sheico, to produce new wetsuits. The first wetsuits made with reclaimed BolderBlack are expected to hit the market in spring 2025.
Mackenzie Warner, Patagonia’s Material Developer, highlighted the ongoing innovation, saying, “At Patagonia, we strive to build the best products and constantly improve everything we do by developing new ways to do things. While collaborating on this material with Bolder Industries, we discovered that recovered carbon black from rubber scraps and Yulex wetsuits can be utilized to not only solution dye wetsuit materials but also black fabrics and trims to make products such as packs and jackets. We are excited to continue to find new ways to use this innovative new material and share it with the industry.”
Eco-diving on the rise
Eco-diving is a travel trend gaining popularity in dive hotspots like the Caribbean, according to a recent Reef-World survey of sustainability in the marine tourism industry. That study found that more than 80 percent of divers are seeking sustainable dive operators that prioritize marine life conservation.
Earlier this year, Sandals Resorts’ newest resort in Saint Vincent became the first resort company to achieve 100 percent Green Fins status. Green Fins is implemented internationally by The Reef-World Foundation and the UN Environment Programme, and is designed to protect coral reefs through environmentally friendly guidelines while promoting sustainable scuba diving and snorkeling.
Surfers are also upping their interest in sustainable surf boards, wetsuits, and gear. More than 250 surfboard manufacturers are now Ecoboard certified. Surf gear giant Rip Curl as well as Patagonia is B Corp Certified. “Statistically, new surfers are significantly more concerned about sustainability than people who have been surfing for a longer period of time,” Jess Ponting, founder and director of the Center for Surf Research and an associate professor at San Diego State University, told Bloomberg last year. “And they’re better able to take action on that concern, given the wider availability of sustainable surfboards and wetsuits and certified sustainable surfing resorts.”
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