How Mormaii Tests and Develops New Wetsuits
Murillo Caldas explains the open-water innovation cycle, field testing routines, and the role athletes play in the process.
Unlike surfing gear that follows strict seasonal collections, Mormaii only updates its open water and diving suits when genuine technical breakthroughs occur. The development process relies on rigorous prototyping, real-world athlete testing, and a culture of trial and error.
In the development of high-performance watersports gear, product release cycles don't always follow the fast pace of fashion. While the surf industry relies on frequent seasonal collections, wetsuits designed for open water and diving evolve strictly around technical advancements.
Real innovation over commercial calendars
According to Murillo Caldas, who leads sports product development for swimming and diving at Mormaii, a new suit only joins the lineup when there is a concrete technological breakthrough to justify it. In endurance sports, athletes prioritize hydrodynamic efficiency, thermal comfort, and freedom of movement, demanding meticulous refinement before any gear hits the water.
Even when updates feature visual appeal—such as fresh prints and custom aesthetic finishes—the functional foundation must remain intact. The hydrophobic SCS (Super Composite Skin) coating, for instance, plays a crucial role in minimizing drag and improving glide through the water, regardless of the suit's exterior design.
Prototyping, field testing, and trial and error
The journey from an initial concept to the final wetsuit requires a rigorous battery of field tests. In Garopaba and Porto Alegre, physical education specialist Argel Pedroso coordinates trials with local teams. Among the test pilots putting triathlon prototypes through their paces is Alejandro, a 16-year-old triathlete and the grandson of Mormaii founder Morongo.
This culture of getting internal staff and partner athletes in the water is deeply rooted in the company's history. Prototypes spend months in the hands of actual athletes to spot flaws in cut, sealing, and mobility long before any official launch. For Murillo, trial and error is an indispensable part of product development: ideas that seem promising on paper are often discarded or re-engineered after the very first stroke in open water.