How Mormaii Developed Its Open-Water Wetsuit Line
Murillo Caldas recalls transitioning from 2000s triathlon suits to swimming-focused neoprene models.
In the early 2000s, Mormaii's first swimming suits were launched under the triathlon label, featuring classic silver styling. Developer Murillo Caldas explains how the sport's evolution and biomechanical demands led to a dedicated category of open-water wetsuits.
In the early 2000s, the Brazilian water sports market experienced the rapid rise of triathlon and major open-water crossings. At the time, Mormaii already dominated the production of rubber wetsuits for surfing and diving, but its entry into competitive swimming began with silver-accented suits designed specifically for triathletes.
From Triathlon to a Distinct Open-Water Identity
The brand's first models—distinguished by silver-and-blue and later black-and-silver colorways—quickly gained ground in race transitions. However, the independent growth of open-water marathons and ocean crossings required a strategic shift in product development.
For Murillo Caldas, head of sports development at Mormaii, separating these concepts was essential. Retaining an exclusive triathlon label created confusion for beginner athletes regarding whether the suit could be worn on the bike or run, whereas pure swimming demanded its own category: thus, a dedicated open-water line was born.
Biomechanics, Buoyancy, and Pattern Design Challenges
Although swimming wetsuits share neoprene rubber as a base with surf and dive gear, they require entirely different outer coatings, finishes, and panel configurations. The equipment's function centers directly on hydrodynamics and supporting proper body alignment in the water.
With the increased buoyancy provided by neoprene around the hips and legs, an athlete's kick shifts from a purely propulsive role to acting as a rudder and balance mechanism. If the cut and thickness are not properly calibrated, swimmers risk kicking above the water surface and wasting energy.
Another critical design element is the collar and shoulder fit. Overly loose necklines create a "scoop effect," allowing water to flood in and transforming the suit into a drag anchor that slows the swimmer down. Conversely, a watertight seal requires supple materials to minimize friction and chafing during long-distance races.
Full-Sleeve, Sleeveless, and Athlete Feedback
The initial influence of imported suits established the near-exclusive use of full-sleeve wetsuits in triathlon, where the maximum swim distance is typically 2.4 miles (3.8 km) in an Ironman. In open-water marathons, however, varying distances and water temperatures opened up discussions around sleeveless designs and fabrics offering greater shoulder elasticity.
The prototyping process revealed that technical feedback varies widely depending on who tests the suit. Differing body types, stroke tempos, and swimming mechanics produce contrasting impressions of the same suit, making input from high-performance swimmers an indispensable step in refining neoprene gear.