The enamel had been redesigned, the manufacturing course of rewritten, and new equipment developed to connect the closure to clothes. “The absence of the tape posed varied manufacturing challenges,” Nishizaki says. “We needed to develop new manufacturing tools and a devoted stitching machine for integration.” The outcome: a lighter, extra versatile system that reduces materials use and environmental impression in contrast with a normal Vislon zipper.
Early adopters are already experimenting. Descente Japan, recognized for technical sportswear, was among the many first to prototype AiryString in 2022. The North Face has chosen the system to be used in its new Summit Series Superior Mountain Equipment. Smaller manufacturers like Earthletica, an eco-conscious swim and efficiency label, have additionally examined it, describing the zipper as “tender, versatile, and virtually silent.”
The impact is seemingly tactile. Clothes transfer extra naturally, lie flatter in opposition to the physique, and really feel much less mechanical. “We repeatedly conduct sturdiness and power exams by stitching AiryString and typical zippers into varied materials,” Nishizaki says. “By way of usability, AiryString provides a lot smoother operability.” That interprets to a softer, slicker glide—the satisfying pull that separates a well-made jacket from an inexpensive one.
Little Components, Huge Change
On the manufacturing facility ground, the advantages add up, too. Conventional zippers devour additional material and dye and require a number of stitching passes. By eradicating the tape, YKK says it trims each materials and labor. “It contributes to lowering work in prospects’ stitching processes,” Nishizaki says. “It additionally reduces fiber use and water consumption within the dyeing course of, decreasing CO₂ emissions.”
The mathematics provides up quick. YKK provides a 100% recycled-material model of AiryString and claims measurable cuts to greenhouse gasoline emissions and water utilization. The impression is magnified by scale: The corporate operates in 70 nations and areas, and its trademark is registered in 180. Once you make billions of zippers a 12 months, these small efficiencies ripple globally.
