From nylon waste to Smoothshell™

What it’s made of, and why it works

Every claim on this page has a number, a method or a document behind it.

Recycling the ocean plastics

From nylon waste to a finished pair, how it is tested, and the documents behind every figure on this page. We can't change the world but we do whatever we can.

From waste to yarn in four steps

Collection
01 / 04

Collection

Fishing nets, industrial plastic waste, leftover yarn and fabric scraps are collected.

Worldwide
Sorting
02 / 04

Sorting

Nylon 6 is separated from everything else, cleaned, shredded and compacted.

Ajdovščina, Slovenia
Depolymerisation
03 / 04

Depolymerisation

The nylon is broken down chemically to its raw material, caprolactam.

Ljubljana, Slovenia
Yarn
04 / 04

Yarn

Caprolactam is polymerised back into Nylon 6 and spun into ECONYL® yarn.

Italy
Where the waste comes from

Aquafil collects nylon waste through its own network in the USA, Egypt, Pakistan, Thailand, Norway and Turkey. Volunteer divers in the Healthy Seas initiative recover lost fishing nets off Belgium, the Netherlands, Italy, Greece and Croatia, and Net-Works helps coastal communities in the Philippines and Cameroon collect and sell discarded nets.

Why chemical regeneration matters

Breaking the nylon down to caprolactam removes impurities that mechanical recycling leaves behind. The result is nylon chemically identical to virgin Nylon 6, and it can be regenerated again.

Smoothshell™ fabric

Smoothshell™ is our original fabric, Smoothshell Light™ the finer version and Highland Smoothshell™ the merino knit for Stealth. [D1].

Smoothshell™

Our original fabric.

In
Globetrotter Boxer, Traveller Trunk, Boxer Regular, Boxer Short, Boxer Short W, Boxer Long W, High String, Metropolitan Top, Paramount Top
Specification
Composition
88% ECONYL® regenerated polyamide, 12% elastane
Yarn
dtex 66
Weight
135 g/m²

Smoothshell Light™

The finer version of Smoothshell™.

In
Bouncy Boxer Brief, Discovery Lightweight Boxer, Cheeky High Waist Thong, Shameless Low Waist Thong
Specification
Composition
87% ECONYL® regenerated polyamide, 13% elastane
Yarn
dtex 44
Weight
130 g/m²

Highland Smoothshell™

The merino knit for Stealth.

In
Men's Long Sleeve Stealth Shirt, Women's Long Sleeve Stealth Shirt, Men's Stealth Pant, Women's Stealth Pant
Specification
Yarn
Merino Nm 85, 16.5 µm (outside); ECONYL® polyamide dtex 44 (inside)
Shirt
Composition
58% merino wool, 42% ECONYL® regenerated polyamide
Pants
Composition
56% merino wool, 41% ECONYL® regenerated polyamide, 3% elastane
Why two faces?

Most merino base layers put the wool against the skin. Ours turns it around: ECONYL® yarn against the skin moves moisture outwards, and the merino on the outside holds warmth even when damp. The knit is seamless and made only for us.

Fit & construction

Patterns built in 3D on real body data, not graded up and down from one fit model.

How a pattern is made

Every pattern starts as a digital prototype. We fit it on 3D avatars built from real body data, simulate how the fabric stretches and presses as the body moves, and correct the pattern before any fabric is cut.

01 / 05

Body data

Various body type avatars are created from real body measurements.

02 / 05

Fabric data

Our own fabrics scanned, so the simulation stretches like the real knit.

03 / 05

Digital samples & simulation

Digital products are fitted to body type avatars to see where they press. Movement is also examined seam by seam. This reduces the need for physical samples, one of the most demanding phases of garment design.

04 / 05

Physical samples & fitting

When the digital samples are ready, physical samples are made from them and fitted on several different body types. The fitting produces a map that shows what needs to change.

05 / 05

Fine tuning and ready patterns

The pattern is changed where the map shows a problem, size by size.

Seams and waistband

Low-profile seams sit off the crease lines, so they are not under load when you bend, sit or stride. The waistband holds without leaving a line.

Leg lengths

Traveller 4″, Globetrotter 6″, Adventurer 9″. A longer leg covers the inner thigh where skin meets skin; a hem that travels is a hem that rubs.

Taking a body measurement with a tape

What 3D design changes

The biggest advantage of 3D pattern design is that we can adjust a single size within a style. On a traditional pattern, a change to one size has to be carried through to every size. When the size changes, the shape changes too.

Production

Where our underwear is made, and the two ways it is made.

Where it is made

Impetus Portugal – Têxteis S.A., a family-owned company in Northern Portugal, makes our underwear from yarn to finished product. The ECONYL® yarn is knitted  into three different Smoothshell™ variations The fabric is  dyed on site. It is then cut to patterns, sewn, quality-checked and packed in the same place. 

Certificates

Impetus' commitment is certified by bluesign®. Its quality system is ISO 9001 certified, and its underwear is OEKO-TEX® STANDARD 100 certified [D2, D3].

Impetus' sustainability

According to Impetus, all its production facilities treat their own water, control their gas emissions and use biomass to heat water. Solar panels cover a large part of the industrial site, 70% of the company car fleet is electric or plug-in hybrid.

Why this matters

The mechanism, in two or three sentences.

Seamless or cut & sew?

Seamless means the garment is knitted to shape on a circular knitting machine, with few or no seams. Cut & sew means the fabric is knitted first, then cut to the pattern and sewn together.

Our Stealth range is seamless. All our other styles are cut and sewn, to patterns made in 3D.

The science behind the underwear

The words on an underwear label and the physics behind them, in plain language.

What do “technical” and “functional” mean?

Technical, in our world, means the pattern and the construction: where the seams sit, how the waistband is built, where the fabric is allowed to stretch and where it is not.

Functional means fit: the underwear stays where you left it, squats, long strides and the saddle included.

What does moisture-wicking mean?

The fabric is made from fibre that does not absorb sweat but conducts it to the outer layers, where it evaporates. Polyamide is hydrophobic: sweat travels along the surface of the fibre and evaporates on the outside of the fabric. Cotton absorbs it and holds it against the skin.

Capillary moisture transport

Moisture travels along the surface of the fibre without soaking in. Liquid moves from wet towards dry, towards where the capillary channels are narrowest and the surface area greatest. In practice this is a property of hydrophobic fibres only.

Why does moisture move away from the body?

Water vapour moves from higher vapour pressure to lower, and vapour pressure rises with temperature. Next to the skin it is warm and humid, further out cooler and drier, so the vapour pushes outwards. Evaporation binds heat, which cools the skin at the same time.

What does breathability mean?

Not ventilation, but the rate at which water vapour passes through a fabric, measured as MVTR in grams per square metre per 24 hours. Under 5,000 is a modest figure, around 10,000 is considered good, over 20,000 is enough for running and the mountains, and the best membranes reach about 40,000. Any figure above zero earns the word, so ask for the number.

Cotton or synthetic: what is the difference?

Synthetic fibres such as polypropylene, polyester and polyamide (ECONYL® among them) are hydrophobic: they do not absorb moisture. Natural fibres are mostly hydrophilic: they absorb moisture into themselves.

Why does wet cotton make you cold?

When cotton binds moisture, air is pushed out, and air is the insulating layer that keeps a person warm. Water conducts heat at about 0.6 W/(m·K), air at about 0.026, so wet fabric moves heat off the skin about 23 times faster than air [1, 2].

Cotton, bamboo, linen and merino

Cotton binds the most moisture; linen dries faster and feels cooler. Bamboo viscose is regenerated cellulose and binds as much moisture as cotton, though it is often sold as moisture-wicking. Of the natural fibres, merino manages moisture best, by a different mechanism: it binds moisture as vapour and stays warm even when wet.

Is synthetic underwear a plastic bag?

A plastic bag keeps you wet because nothing crosses a solid film. Smoothshell™ is a knit, not a film: water vapour moves out and air moves in. Synthetic is not the problem. Sealed is. In technical underwear the pattern and the knit matter as much as the fibre: the best hydrophobic fibre fails if the knit or the cut is done poorly.

Care instructions

Heat and harsh chemicals are what shorten the life of these fabrics. Avoid both and a pair lasts for years.

All underwear and tops

Smoothshell™ and Smoothshell Light™

40 °C
Machine wash at 40 °C max, gentle cycle, under 1,000 rpm. Hand wash is best.
Bag
Use a laundry bag, away from zips, hooks and buttons.
Colours
Wash with similar colours.
No dryer
No tumble dryer. Heat destroys the elasticity.
No chemicals
No softener, bleach or stain remover.
No iron
Do not iron.
Stealth shirt and pants

Highland Smoothshell™

Air
Wash rarely. Merino often just needs airing.
Cold
Cold hand wash. Machine only on a wool or silk program under 30 °C.
Bag
Use a laundry bag, away from zips, hooks and buttons.
Colours
Wash with similar colours.
No dryer
No tumble dryer, no dry cleaning.
No chemicals
No softener, bleach or stain remover.
No iron
Do not iron.
Why these rules: Smoothshell™ and Smoothshell Light™
Elastane gives the fabric its recovery, and heat breaks it down: a tumble dryer or an iron does in minutes what a year of wear does not. Softeners, bleach and stain removers are corrosive to the fibres.
Why these rules: Highland Smoothshell™
Merino often just needs airing. Any washing program other than wool or silk under 30 °C will damage the garment.
Sources
  1. Garg, S., Midha, V. K., & Sikka, M. (2022). Studies on thermal comfort of multi-layered fabric assembly after wetting with sweat and distilled water. Journal of Industrial Textiles, 52. doi.org/10.1177/15280837221110105
  2. Sanak, T., Putowski, M., Krzeptowski-Sabała, S. et al. (2025). Conductive heat loss in simulated outdoor settings: a preliminary experimental human study. Int J Emerg Med 18, 235. doi.org/10.1186/s12245-025-01034-8

Documents

DocumentIssued byValid until
D1 Fabric data sheet, V49 · 46Z · 07J Impetus Portugal – Têxteis S.A. –
D2 OEKO-TEX® STANDARD 100, no. 62, product class II, 62 CITEVE 31.5.2027
D3 ISO 9001:2015 quality management, 1999/CEP.865 APCER 16.11.2027
D4 GRS · RCS · RWS · OCS scope certificate, IDF-25-944869 IDFL Laboratory and Institute 29.6.2027