Xenon Athletics Australia: Unitard Built on Recycled Nylon/Spandex Power Mesh Knit
Xenon Athletics, based in Australia, needed a unitard that delivered recycled content traceability without moving away from a clean, commercial silhouette. The finished fabric was Recycled Nylon/Spandex Power Mesh Knit.
Project brief and fabric selection
The fabric selected combines Power Mesh Knit (high modulus warp knit) with regenerated polyamide with elastane, giving lower footprint with identical performance. Construction is high modulus warp knit at 100-150 GSM. The brief also asked for plus controlled modulus. Each lot was checked against GRS transaction certificate before cutting began.
Construction and fit decisions
Pattern and construction were adjusted around the chosen fabric: seam placement moved away from high-friction areas, stitch density was matched to the elastane content, and the fit block was revised once the first wear trial showed the panel tension distribution. The development brief set the outcome as every lot shipped with GRS transaction certificates.
Dyeing and finishing approach
Finishing was limited to processes that support recycled content traceability. Soft handle came from construction rather than heavy softening, which keeps performance stable through repeated washing. Consistency between repeat lots mattered more to Xenon Athletics than an isolated best result.
Measured results
Measured outcome: every lot shipped with GRS transaction certificates, verified by GRS transaction certificate. Size sets were checked after five home washes to confirm that dimensional change stayed inside the agreed tolerance before bulk release. Fabric Recycled Nylon/Spandex Power Mesh Knit supplied the base behaviour for recycled content traceability.
Repeat order performance
The style moved to repeat orders after two seasons. Bulk fabric is now booked against a fixed recipe, with test reports issued per lot, and the Power Mesh Knit construction is used for additional colourways in the same programme. The Australia market requires documentation, so reports shipped with every lot.
