The Zipper Is Getting Its First Major Upgrade in 100 Years
The teeth were redesigned, the manufacturing process rewritten, and new machines developed to attach the zipper to clothing. “The lack of tape caused various production problems,” says Nishizaki. “We had to develop new manufacturing 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.
The first users are already experimenting. Descente Japan, known for its technical sportswear, was among the first to prototype AiryString in 2022. The North Face selected the system for use in its new Summit Series Advanced Mountain kit. Smaller brands like Earthletica, an eco-conscious swim and performance brand, have also tested it, describing the zipper as “soft, flexible and almost silent.”
The effect is apparently tactile. Clothes move more naturally, lie flatter against the body and feel less mechanical. “We repeatedly carry out durability and strength tests by sewing AiryString And conventional zippers in various fabrics,” says Nishizaki. “In terms of usability, AiryString offers much smoother operability.” This results in a softer, smoother glide – the satisfying pull that separates a well-made jacket from a cheap one.
Small parts, big change
In the factory, the benefits also add up. Traditional zippers use more fabric and dye and require multiple passes of sewing. By removing the tape, YKK claims to reduce both material and labor. “This helps reduce sewing work for customers,” says Nishizaki. “It also reduces fiber use and water consumption in the dyeing process, thereby reducing CO₂ emissions.”
The calculations add up quickly. YKK offers a version of AiryString made from 100% recycled materials and claims measurable reductions in greenhouse gas emissions and water consumption. The impact is amplified at scale: the company operates in 71 countries and regions, and its brand is registered in 177. When you do billion zippers per year, these small efficiency gains ripple globally.
