The clouds are getting their first major upgrade in 100 years

Teeth were redesigned, the manufacturing process was rewritten, and new machines were developed to attach closures to garments. “The absence of tape presented various production challenges,” Nishizaki says. “We had to develop new manufacturing equipment and a custom 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 experimenting. Descente Japan, known for its technical sportswear, was among the first companies to prototype the AiryString in 2022. North Face has selected the system for use in its new Summit Series Advanced Mountain Kit. Smaller brands like Earthletica, an eco-friendly swim and performance brand, have also tested it, describing the zipper as “soft, flexible and almost silent.”

The effect seems to be tangible. Clothes move more naturally, lie flat against the body, and appear less mechanical. “We frequently perform durability and strength tests with our AiryString stitching and “In terms of ease of use, AiryString offers smoother operation,” says Nishizaki. This translates to a smoother, smoother glide, the satisfying pull that separates a well-made jacket from a cheap one.

Small parts, big change

On the factory floor, the benefits are also increasing. Traditional zippers consume additional fabric and dye and require multiple stitching passes. By removing the tape, YKK says it cuts both materials and labor. “It reduces work on customers’ sewing operations,” says Nishizaki. “It also reduces fiber use and water consumption in the dyeing process, reducing carbon dioxide emissions.”

The math adds up quickly. YKK offers a 100 percent recycled material version of the AiryString and claims measurable reductions in greenhouse gas emissions and water use. The impact is widely amplified: the company operates in 71 countries and regions, and its trademark is registered in 177 countries. Billions of clouds per year, these small efficiencies spread globally.