The Zipper Is Getting Its First Major Upgrade in 100 Years

The teeth were redesigned, the manufacturing process was rewritten and new machinery was developed to close with the clothing. “The absence of tape created several production challenges,” says Nishizaki. “We had to develop new production equipment and a dedicated sewing machine for the integration.” The result: a lighter, more flexible system that reduces material use and environmental impact compared to a standard Vislon zipper.

Early adopters are already testing. Descent JapanKnown for its technical sportswear, Airstring debuted its prototype in 2022. The North Face chose the system for its new use Summit Series Advanced Mountain Kit. Smaller brand preferences EarthletikaAn eco-conscious swim and performance label, tested it, describing the zipper as “soft, flexible and almost silent”.

The effect is clearly tangible. Garments move more naturally, lie against the body and feel less mechanical. “We test durability and strength by repeatedly stitching AiryString And “Conventional zippers on different fabrics,” says Nishizaki. This translates to a softer, slicker glide—a satisfying pull that separates a well-made jacket from a cheap one.

Small parts, big changes

On the factory floor, facilities also add up. Traditional zippers use extra fabric and dye and require multiple sewing passes. By removing the tape, YKK says it cuts both material and labor. “This contributes to reducing work in the sewing process for customers,” says Nishizaki. “It also reduces fiber use and water use in the dyeing process, reducing CO₂ emissions.”

The math adds up quickly. YKK offers a 100 percent recycled-materials version of the AiryString and claims measurable cuts in greenhouse gas emissions and water use. Influence is magnified by scale: the company operates in 71 countries and territories and its trademarks are registered in 177. when you billion Every year of the zipper, this little functionality spreads worldwide.