The plastic parts of the Corsuit are made of injection-moulded polycarbonate (PC). PC is an engineering thermoplastic, and exhibits excellent durability and impact resistance, while retaining just a little flexibility. This allows it to conform to the movements of the swimmer, while still being rigid enough to provide adequate feedback.

whole mould2 copy2

Above is one of the injection moulds that helps make the support wing of the Corsuit. These moulds are precision-machined from blocks of steel, and are exceptionally tough in order to withstand the extreme pressure produced by the injection process. This makes for a system that can produce the Corsuit in mere seconds.