Designing Circular, Long-Life Sustainable Swimwear

Table of Contents

1. Introduction — Why Circular Swimwear Matters

2. Environmental Impact of Modern Swimwear

3. What “Circular Swimwear” Really Means

4. Core Principles of Circular Design

5. Materials That Enable a Circular Swimwear System

6. Designing Durable, Long-Lasting Swimwear

7. Designing for Recycling & Disassembly

8. Breakthrough Innovations Transforming Sustainable Swimwear

9. Global Brand Case Studies

10. End-of-Life Recycling Systems

11. Chemical vs Mechanical Recycling

12. Recycling Challenges & New Research

13. Practical Roadmap for Brands

14. Consumer Guide to Sustainable Swimwear

15. The Future of Circular Swimwear

16. Frequently Asked Questions

17. References

1. Introduction — Why Circular Swimwear Matters

Most modern swimwear still relies on synthetic, petroleum-based fibres such as nylon, polyester, and elastane. These fibres deliver excellent stretch, support, and chlorine resistance, but they also drive microplastic pollution, carbon emissions, and persistent textile waste.

According to research summarised by the European Environment Agency in 2022, building on a global study by Boucher and Friot (2017), around 35% of primary microplastics released to the oceans come from washing synthetic textiles such as sportswear and swimwear.[1] The Ellen MacArthur Foundation estimates that roughly half a million tonnes of plastic microfibres enter the ocean every year from washing clothes alone.[2]

Swimwear is part of this challenge, shedding fibres through:

• Swimming, where sand, salt, and UV exposure abrade the fabric

• Machine washing and rinsing at home or in hotels

• Everyday friction during wear, drying, and storage

Meanwhile, the EU Strategy for Sustainable and Circular Textiles (2022) has set a clear direction: by 2030, textile products placed on the EU market should be more durable, repairable, and recyclable, and made largely from recycled fibres.[3] Extended producer responsibility (EPR) rules under discussion in the EU will also require brands to take more responsibility for textile waste and end-of-life.

Circular swimwear is one of the most promising approaches to align with these expectations. By rethinking design, materials, and end-of-life systems, brands can keep fibres in use longer, recover them at scale, and drastically reduce environmental harm.

This guide offers a global, brand-friendly, yet technically grounded overview of circular swimwear—helping manufacturers, designers, retailers, and conscious consumers understand what truly sustainable swimwear looks like and how to get there.

2. Environmental Impact of Modern Swimwear

2.1 Synthetic Fibres and Microplastics

Most swimwear is produced from nylon (polyamide), polyester (PET), and elastane (spandex). These fibres do not biodegrade under normal environmental conditions. When swimwear is worn, washed, and eventually disposed of, friction and mechanical stress cause the fibres to break into tiny fragments called microfibres.

Based on global estimates, washing synthetic textiles is one of the largest sources of primary microplastics entering the oceans, responsible for roughly one-third of total releases.[1][2] These microfibres accumulate in:

• Rivers, coastal zones, and open oceans

• Marine sediment and beach sand

• Fish, shellfish, and other marine organisms

• Human food chains and drinking water sources

Synthetic microfibres can also absorb and transport persistent chemicals, including pesticides, heavy metals, and industrial pollutants. Over time, this combination of plastic fragments plus chemical load can disrupt marine ecosystems and threaten biodiversity.

Even fabrics marketed as “eco-friendly” (like recycled polyester) can release microfibres if the yarns and fabric structures are not carefully engineered to minimise shedding. The goal is not only to switch materials, but to optimise the entire system: fibres, yarns, knitting, finishing, and consumer care.

2.2 Waste and Landfill Impact

Many swimwear products are made from mixed fibre blends, such as nylon-elastane or polyester-elastane combinations. These blends are difficult to separate at the end of life, making them hard to recycle. As a result, most worn-out swimwear ends up in landfill or in low-value downcycling streams. Globally, it is estimated that only about 1% of textiles are recycled into new textiles, highlighting the scale of the challenge.[2]

Environmental implications include:

• High energy use and carbon emissions during fibre and fabric production

• Chemical effluents from dyeing and finishing processes

• Persistent textile waste in landfills for decades or even centuries

• Loss of valuable materials that could otherwise be recovered and reused

2.3 Why Circularity Matters for Swimwear

Circularity transforms swimwear from a linear model (make → use → throw away) into a circular system (design → use → repair → reuse → recycle → regenerate).

In a circular swimwear system, brands intentionally:

• Choose materials that can be recycled or safely returned to nature

• Design products to last longer and be easier to repair

• Minimise material waste at the cutting and manufacturing stages

• Set up or join take-back and recycling programmes

• Collaborate across the value chain to recover materials at scale

This approach aligns with policy directions such as the EU Strategy for Sustainable and Circular Textiles (2022) and broader climate goals under the Paris Agreement.[3]

3. What “Circular Swimwear” Really Means

Circular swimwear is not just about using recycled fabrics. It is about rethinking the entire product system from fibre to end-of-life and aligning with emerging regulations, voluntary standards, and best practice guidelines.

A truly circular swimwear product typically:

• Uses recycled or renewable materials from credible supply chains (e.g., certified under GRS or similar schemes)[4]

• Is designed with mono-material constructions where possible to enable efficient recycling

• Delivers high durability to prolong use and reduce replacement frequency

• Is compatible with mechanical or chemical recycling technologies

• Has a clear path for take-back or collection when worn out

• Includes transparent labelling and care instructions that support longevity and safe recycling

Circularity is therefore a design mindset, a material strategy, and an infrastructure challenge. It requires coordination between fibre producers, textile mills, brands, retailers, consumers, and recyclers.

4. Core Principles of Circular Design

Circular design in swimwear builds on widely recognised circular economy principles. In simple terms, it focuses on three main goals, often highlighted in circular economy frameworks:

1. Eliminate waste and pollution from design and production.

2. Keep products and materials in use at their highest value for as long as possible.

3. Help nature recover by reducing extraction and supporting regenerative systems.

For swimwear, these principles apply to everything from fibre selection and pattern cutting to packaging, logistics, communication, and end-of-life solutions.

5. Materials That Enable a Circular Swimwear System

5.1 Mono-Materials

Mono-material swimwear uses just one fibre type in the main fabric. This dramatically simplifies recycling because recycling plants can process a single polymer stream without complex separation steps.

Advantages include:

• Easier sorting and identification at recycling facilities

• Higher-quality recycled outputs

• Compatibility with advanced chemical recycling processes

• Fewer contaminants and less waste

Typical mono-material options for swimwear include:

• 100% nylon (polyamide 6 or 6.6)

• 100% polyester

The main challenge is that removing elastane reduces elasticity. However, new yarn engineering and fabric constructions are emerging to create stretch and comfort without traditional elastane blends.

5.2 Recycled and Regenerated Fibres

Regenerated and recycled fibres are central to circular swimwear. One of the best-known examples is ECONYL®, a regenerated nylon made from:

• Discarded fishing nets

• Industrial plastic waste

• Textile scraps

According to Aquafil, ECONYL® regenerated nylon can reduce the global warming impact of nylon by up to 90% compared with traditional nylon made from oil, avoiding more than 65,000 tonnes of CO2-equivalent emissions per 10,000 tonnes of ECONYL® raw material.[5] This makes it a strong fit for reducing climate impacts in swimwear, assuming responsible sourcing and processing.

Other recycled materials used in swimwear include:

• Recycled polyester from post-consumer bottles or industrial waste

• Recycled polyamide blends from textile offcuts

Common materials used in more circular swimwear include:

5.3 Verified Recycled Content and Safety Standards

Certifications and standards help verify claims about recycled content and chemical safety. For example, the Global Recycled Standard (GRS) is a full product standard that tracks recycled raw materials through the supply chain and includes environmental and social criteria for processing facilities.[4]

Meanwhile, labels like OEKO-TEX® STANDARD 100 test textiles for a wide range of harmful substances and set strict limit values for chemicals such as certain dyes, heavy metals, and PFAS, helping protect consumer health.[6] The bluesign® system focuses on chemical management and process control across the textile supply chain, aiming to minimise emissions to air, water, and soil and ensure safer products for people and the environment.[7]

6. Designing Durable, Long-Lasting Swimwear

Circular products must first be durable. The longer a swimsuit remains in active use, the fewer replacements are needed—and the lower its impact per wear.

6.1 Key Aspects of Durability

• Chlorine resistance: Essential for pool use, extending the usable life of the garment.

• UV resistance: Protects fibres from degradation under sunlight.

• High elastane recovery or stretch engineering: Maintains fit and shape over many uses.

• Abrasion resistance: Reduces damage from sand, decks, and washing, which also helps lower microfibre shedding.

6.2 Reinforced Seams and Construction

Reinforced seams, double stitching, and carefully engineered pattern placement reduce the likelihood of splits and tears. Construction quality is as important as fabric choice when it comes to lifespan.

6.3 Avoiding Problematic Mixed Materials

While small amounts of elastane are often necessary in high-performance swimwear, unnecessary mixing of multiple fibres can severely limit recyclability. Where possible, brands should:

• Use single-polymer fabrics

• Limit elastane content or confine it to replaceable components

• Separate functional zones (e.g., removable support panels) for easier recycling

7. Designing for Recycling & Disassembly

Design for disassembly means planning from the start how a product will be taken apart and recycled when it reaches the end of its life.

7.1 Minimal Trims and Accessories

Zippers, metal rings, decorative hardware, and complex trims may look appealing but complicate recycling. A more circular approach:

• Reduces unnecessary metal or plastic components

• Uses detachable or standardised trims where needed

• Prioritises functional simplicity with elegant design details

7.2 Clear Labelling for End-of-Life

Labels should go beyond basic fibre content and provide:

• Precise material breakdown (e.g., 100% PA6, 78% recycled PA / 22% elastane)

• Recyclability guidance (e.g., “Designed for chemical recycling where facilities exist”)

• Care instructions that reduce microfibre shedding and prolong life

7.3 Lessons from Fully Recyclable Designs

Some brands are already experimenting with elastane-free designs and mono-polymer constructions that can be fully recycled. These pilot projects demonstrate that, with thoughtful design and fabric innovation, high-performance swimwear can be compatible with large-scale recycling solutions.

8. Breakthrough Innovations Transforming Sustainable Swimwear

8.1 ECONYL® and Regenerated Nylon

ECONYL® turns waste such as ghost fishing nets and industrial nylon scrap into high-quality yarn. The process includes:

1. Collection of nylon waste from oceans and land-based sources

2. Sorting and cleaning

3. Depolymerisation to break the nylon down to its base components

4. Repolymerisation into new nylon yarn

Industry life cycle assessments published by Aquafil indicate that ECONYL® regenerated nylon can cut global warming potential by up to 90% compared with nylon from virgin fossil resources, under specific scenarios and system boundaries.[5] This makes it an important material for brands looking to align with science-based climate targets.

8.2 Lycra XTRA LIFE™ and Enhanced Durability

Lycra XTRA LIFE™ is engineered to resist chlorine, heat, and body oils better than conventional elastane, helping swimwear maintain its shape and support over many more uses. Combined with recycled base fibres, it supports both durability and circular design goals, although recyclability for elastane-containing fabrics still depends on future chemical recycling solutions.

8.3 Advances in Chemical Recycling

Emerging chemical recycling technologies can:

• Separate elastane from polyamide or polyester

• Depolymerise polyamide 6 into monomers that can be turned into new nylon

• Handle mixed and coloured textiles more efficiently than traditional mechanical recycling

These innovations are especially important for swimwear, where complex blends have traditionally been a barrier to high-quality recycling.

9. Global Brand Case Studies

A growing number of brands are leading the shift to circular swimwear by combining better materials, smarter design, and social or environmental impact initiatives. The examples below are illustrative and based on publicly available brand information.

These examples show that circular swimwear can integrate environmental performance, strong design, and meaningful social impact. They also highlight the importance of third-party certifications and transparent communication when presenting sustainability claims.

10. End-of-Life Recycling Systems

End-of-life solutions are crucial for closing the loop. Instead of sending old swimwear to landfill, take-back and collection schemes offer new life to valuable materials and support textile-to-textile recycling pilots.

10.1 Take-Back and Collection Schemes

Some retailers offer in-store or mail-in programmes where customers can return unwanted clothing, including swimwear, for reuse, recycling, or energy recovery. Examples include:

• Retail donation schemes that resell or recycle returned garments

• Partnerships with specialist recyclers for neoprene and technical gear

• Programmes that provide vouchers or discounts as incentives

10.2 Typical Regeneration Process

The journey from waste to regenerated nylon can be summarised as:

Well-designed take-back schemes can significantly reduce textile waste by keeping materials in circulation instead of sending them to landfill and can support future compliance with extended producer responsibility policies.

11. Chemical vs Mechanical Recycling

When discussing circular swimwear, it is important to understand the difference between mechanical and chemical recycling.

For tightly engineered products like swimwear, chemical recycling is particularly promising because it can handle blends and contaminated materials more effectively, while maintaining fibre performance—although industrial-scale infrastructure is still developing.

12. Recycling Challenges & New Research

Despite rapid progress, several challenges remain for fully circular swimwear:

• The difficulty and cost of separating elastane from other fibres

• Limited large-scale textile recycling infrastructure in many regions

• Contamination from dyes, finishes, and mixed components

• Economic barriers to collecting and transporting worn swimwear

Research teams and innovative companies are working on more efficient, lower-impact processes to break down complex textiles and upgrade recycled outputs. Some are exploring new catalysts and processes to depolymerise polyamide elastane blends more sustainably, while others are incorporating additives to improve the performance of recycled fibres.

Brands can support these efforts by:

• Designing products that are easier to recycle from the start

• Collaborating with recyclers to test new processes

• Sharing data and feedback to accelerate innovation

13. Practical Roadmap for Brands

For brands, transitioning to circular swimwear is a journey. The following steps provide a practical roadmap to get started and continually improve. They can be combined with internal targets or external frameworks such as science-based climate targets and upcoming EU textile regulations.

Step 1: Choose Renewable or Recyclable Materials

• Prioritise regenerated nylons, recycled polyesters, and responsibly sourced natural fibres.

• Use third-party standards such as GRS to verify recycled content and supply chain traceability.[4]

Step 2: Design for Durability and Performance

• Invest in fabrics and constructions that resist chlorine, UV, and abrasion.

• Use fit and support solutions that maintain performance over time, supported by real-world wear tests where possible.

Step 3: Optimise Cutting and Manufacturing

• Adopt zero-waste or low-waste cutting techniques.

• Reuse offcuts in accessories, linings, or new product lines.

Step 4: Plan for End-of-Life

• Set up or join take-back programmes for worn swimwear.

• Partner with recyclers that can handle your primary materials and track the volumes collected.

• Explore pilots for textile-to-textile recycling of your products and publish results where possible.

Step 5: Improve Transparency and Communication

• Share material origins, certifications, and production details using clear, non-misleading language.

• Provide care and recycling guidance on labels, packaging, and product pages.

• Educate wholesale partners about your sustainability goals and how they relate to regulations like the EU textile strategy.[3]

Step 6: Collaborate and Iterate

• Work with mills, recyclers, NGOs, and research labs to test new materials and processes.

• Track and report progress using clear metrics, such as share of recycled fibres, products designed for recycling, or CO2 saved per collection programme.

Brands that follow this roadmap not only reduce their environmental footprint, but also build stronger trust, differentiation, and long-term customer loyalty.

14. Consumer Guide to Sustainable Swimwear

Consumers are powerful drivers of change. By choosing durable and responsibly made swimwear, caring for it properly, and recycling it at the end of its life, you can significantly reduce your impact.

14.1 How to Choose Sustainable Swimwear

• Look for regenerated or recycled materials (e.g., ECONYL®, recycled polyester).

• Check for certifications that indicate safer chemicals and responsible production (e.g., OEKO-TEX® STANDARD 100, bluesign®-approved fabrics).[6][7]

• Choose brands that openly share information about their factories and materials.

• Support companies that produce in small batches and reduce overproduction.

• Opt for timeless designs that you will enjoy wearing for many seasons.

14.2 Care and Maintenance Tips

Good care can dramatically extend the life of your swimwear:

• Rinse your swimsuit in cool, fresh water after swimming to remove chlorine and salt.

• Avoid leaving a wet suit in a closed bag for long periods.

• Wash with mild soap or gentle detergent and avoid bleach or fabric softeners.

• Dry your swimwear in the shade and avoid direct sunlight or tumble drying.

• Store flat or gently folded to prevent stretching and distortion.

14.3 Participating in Recycling Programmes

Many initiatives now accept old swimwear, wetsuits, and pool accessories for recycling. Depending on your region, these may include:

• Pool and leisure-centre collection schemes for flip-flops, goggles, caps, and floats

• Brand-led take-back schemes that accept worn swimsuits and rash vests

• Specialist recycling boxes for neoprene gear and watersports equipment

By using these programmes, you help keep valuable materials out of landfill and support the growth of textile-to-textile recycling.

15. The Future of Circular Swimwear

The next generation of swimwear will likely be shaped by a combination of new materials, smarter design, and digital tools, as well as evolving regulations in key markets.

15.1 Emerging Materials and Technologies

• Bio-engineered fibres from algae, bacteria, or regenerative crops that reduce reliance on fossil fuels.

• Plant-based synthetics using inputs like castor beans or corn sugar to create stretch fibres.

• Mono-polymer designs where all fabric components use a single type of polymer for easy recycling.

• Digital product passports that store information on materials, production, and recycling options to support EPR and consumer transparency.[3]

15.2 Industry Collaboration

Collaboration between brands, fibre producers, and recyclers is accelerating innovation. Some brands are already using high shares of recycled polyamide and polyester, combined with digital tools to track each product's journey and end-of-life options.

15.3 Shifting Consumer Behaviour

As more people choose eco-conscious options, demand for circular swimwear will continue to grow. At the same time, brands must work to close the gap between intentions and actions by:

• Offering competitive price points and long-lasting quality

• Making sustainable options easy to find and understand

• Providing convenient take-back and repair options

Circular swimwear is becoming less of a niche and more of a new standard for responsible fashion.

16. Frequently Asked Questions

What does “circular swimwear” mean?

Circular swimwear is designed to last a long time, use lower-impact materials, and be recyclable or regenerable at the end of its life. It aims to keep fibres in use for as long as possible instead of sending them to landfill, in line with circular economy principles.

How can I tell if swimwear is recyclable?

Check the label for mono-material constructions such as 100% nylon or 100% polyester, and look for recycling guidance or take-back programmes on the brand’s website. Swimwear made from a single polymer is generally easier to recycle, especially as chemical recycling develops.

Why should I choose durable swimwear?

High-quality, durable swimwear needs to be replaced less often. This saves you money over time and reduces the overall environmental impact associated with production, shipping, and disposal.

What is ECONYL® and why is it important?

ECONYL® is a regenerated nylon made from waste such as discarded fishing nets and industrial nylon scrap. According to Aquafil’s life cycle studies, it can reduce the global warming impact of nylon production by up to 90% under specific conditions, helping brands move towards climate goals.[5]

Can mixed-material swimwear be recycled?

It is more difficult, but not impossible. Emerging chemical recycling technologies can handle some mixed polyamide 6 blends, though industrial capacity is still limited. From a design perspective, mono-materials remain the most efficient and scalable route for high-quality recycling.

How should I care for my swimwear to make it last?

Rinse in cool water after each use, wash gently with mild soap, avoid high heat and direct sun when drying, and store flat or neatly folded. These steps help maintain elasticity, colour, and fabric strength and may also reduce microfibre shedding over time.

Are there eco-friendly packaging options for swimwear?

Yes. Many brands now use packaging made from recycled cardboard, paper envelopes, compostable mailers, or reusable pouches. Avoiding single-use plastic packaging is an easy way to reduce overall impact.

How can I make the most sustainable choice as a consumer?

Choose timeless designs you truly love, from brands that share clear information about their materials and supply chain. Take care of your swimwear, repair it where possible, and use take-back or recycling options at the end of its life. Supporting brands certified under credible standards like OEKO-TEX® or bluesign® can also help.[6][7]

17. References

1. Boucher, J., & Friot, D. (2017). Primary Microplastics in the Oceans: A Global Evaluation of Sources. International Union for Conservation of Nature (IUCN). Summary cited via European Environment Agency (2022).

2. Ellen MacArthur Foundation. (2017). A New Textiles Economy: Redesigning Fashion’s Future. Estimates around half a million tonnes of plastic microfibres entering the ocean annually from washing textiles.

3. European Commission. (2022). EU Strategy for Sustainable and Circular Textiles. Part of the European Green Deal and Circular Economy Action Plan, setting direction for durable, repairable, and recyclable textile products.

4. Textile Exchange. (2021). Global Recycled Standard (GRS). A full product standard to verify and track recycled raw materials and processing criteria through the supply chain.

5. Aquafil / ECONYL®. (2020–2021). ECONYL® Regenerated Nylon Environmental Benefits. Company LCA data indicating up to 90% reduction in global warming potential compared with nylon from oil under defined conditions.

6. OEKO-TEX® Association. (2022). STANDARD 100 by OEKO-TEX® Factsheet. Global independent testing and certification system for textiles, covering harmful substances and environmental substance classes.

7. bluesign technologies ag. (2022–2024). bluesign® System and CHEMICAL ASSESSMENT. Criteria and tools for chemical management and sustainability in the textile and leather industry supply chains.