Orca Lab: Surfing and Innovation

The neoprene wetsuit, introduced in the 1950s by pioneer Jack O’Neill, revolutionised surfing by allowing surfers to defy the cold water. At the beginning, the suits were thick and rigid, aimed at retaining body heat. However, over the decades, wetsuits have evolved thanks to advancements in materials and technology. From different zippers and thicknesses in the ‘60s and ‘70s to the use of closed cell neoprene in the ‘80s, buoyancy and durability has improved. Today, the suits are lighter, more flexible and efficient, thanks to innovations that prioritise performance and thermal protection, allowing surfers to enjoy the waves in the most extreme conditions.

 

 

Orca has established itself as the leading brand in the development of top quality wetsuits thanks to 30 years of experience in their design and production, with a renewed commitment to innovation through the project Orca Lab. The Lab is where the characterisation of materials, the development of new combinations and advancements in sustainability take place. Orca wetsuits are predominantly produced using neoprene extracted from the Yamamoto limestone, a material of natural origin with exceptional properties in terms of durability, elasticity and thermal retention. Through continuous study, the best materials for each wetsuit panel are selected, which results in the optimum combination of flexibility, comfort and durability.  

 

Flexibility is key to guaranteeing mobility for surfers and we take it into account when we design specific panels for areas that require more elasticity, like the shoulders. At the same time, we ensure that other panels retain heat or add extra comfort by combining a careful balance of thermal and elastic properties.

 

The latest technologies are also incorporated into the wetsuit designs, such as the use of sealed seams and thermal panels, which improve both the product’s performance and durability. We prioritise quality, guaranteeing our suits offer not only comfort and a good fit, but also a long life, so that surfers can enjoy them for longer.

 

 

In terms of sustainability, we are aware of the environmental impact of the materials used in the production of wetsuits. In the case that the natural or biodegradable products aren’t yet completely viable, we opt for Yamamoto neoprene, obtained from limestone, which leaves a better ecological footprint and maintains its properties for longer compared to traditional neoprene.

 

The creation process of an Orca wetsuit takes roughly two years from the birth of the idea to its launch on the market. During this time, prototypes are developed and these are subject to rigorous testing, in the laboratory and outside, in order to ensure the quality standards are met. The testing involves aspects such as durability and fatigue, elasticity and elongation, resistance to abrasion, water absorption and filtration, among others. 

 

The creation of high quality wetsuits presents various challenges. At Orca we put special care into the manual processes involved, ensuring consistency in mass production and keeping rigorous control over each stage in the process. This focus has allowed the brand to offer high-performing products with a long service life and to respond quickly to any need or adjustment that may arise in the production process. 

 

Ultimately, at Orca we continue to strive towards innovation and sustainability, prioritising the quality of our products and surfers’ satisfaction, in the hope that they find an ally in their wetsuits when faced with the most demanding conditions in the ocean.