Other Critical Factors Beyond Thickness

The thickness of the neoprene is just one part of the equation. The quality of the neoprene is equally important:

NEOPRENE TYPE:

Standard Neoprene: Heavier, less flexible, and absorbs more water.

Super-Stretch / High-Grade Neoprene: Much more flexible, lighter, and provides better warmth for its thickness. This allows a 3 mm high-end suit to be as warm as a 4 mm standard suit while offering superior mobility.

Limestone Neoprene: A more eco-friendly option that is often softer and more flexible.

SEAMS:

Flatlock Stitching: Suitable for warm water. The seams are not fully waterproof.

Glued Blind Stitching (GBS): The panels are glued together and then stitched from the inside. This prevents water from flushing through the stitch holes, greatly improving warmth.

Liquid Taped Seams (Sealed): The internal seams are sealed with a liquid rubber tape, making the suit almost completely watertight. This is the warmest and most advanced seam construction.

LININGS:

Nylon Linings: Standard.

Fleece / Lined Panels: Some suits have a plush, fleece-like lining on the torso panel for added warmth and comfort.

Summary: The Design Process

Start with Water Temperature: Use the chart as a baseline.

Define the User & Activity: Adjust the baseline thickness up (for less activity / cold-natured users) or down (for high activity / warm-natured users).

Design the Zoning Map: Decide on the differential thickness pattern (e.g., 4/3 mm, 5/4/3 mm) to maximize core warmth while preserving mobility in key areas.

Select Neoprene and Construction Quality: Choose high-stretch neoprene and sealed seams for colder water or higher performance needs. This can sometimes allow you to use a slightly thinner suit without sacrificing warmth.