At FCS, performance and purpose drive everything we do—right down to the socks. Designed for surfers who live on the move, our new travel and surf socks are built to handle the elements and perform under pressure. We sat down with the team behind the design to dive into the inspiration, materials, and innovation that make these socks a cut above the rest.
What inspired you to create socks specifically for travellers and surfers?
I realised there is a significant gap in the surf and travel market for quality, purpose-built surf and travel socks. Aside from Patagonia, only outdoor, hunting, and snow brands generally offer suitable merino wool options. Most surf brands tend to provide bulk-pack cotton or synthetic socks that are not specifically designed for the needs of on-the-go surfers and travellers.
Was there a moment or trip that made you realise current socks weren’t cutting it?
It was not a particular moment or trip; however, I noticed many surfers wearing synthetic or cotton socks before and after surfing to warm their feet. However, cotton socks stop providing warmth once they absorb moisture and lose all insulation when wet. On the other hand, synthetic socks do wick moisture away, but they lack breathability, causing feet to sweat. So, I recognised there had to be a better sock option.
What materials did you choose, and why?
Merino wool became our material of choice. Specifically, we selected two types of high-tech wool fibres: Nuyarn for the top of the foot and cuff, and Herculan for underfoot. Nuyarn was chosen for its high-performance properties, such as thermoregulation (keeps you warm when it's cold and cool when it's hot), moisture-wicking and fast-drying capabilities, natural elasticity to move with your body, and extreme durability. Herculan (also known as carpet wool or strong wool) was selected for its high abrasion resistance and slip-resistant properties in high-impact areas, such as underfoot zones. This wool was traditionally used in the carpet industry for its durability, but due to innovation, it can now be used in the apparel sector. Herculan also shares the same performance characteristics as Nuyarn, but with the added advantage of enhanced durability.
How do these socks handle moisture, saltwater, and sand?
The FCS socks manage moisture exceptionally well. Unlike cotton or synthetic materials, our merino wool socks can absorb up to 14-16% moisture, compared to just 2-4% for synthetic materials. When exposed to saltwater and sand, the socks become wet and sandy. However, a significant advantage is that they keep your feet warm even when damp. I've worn these socks on the beach while walking through the surf and sand. Once finished, I simply rinsed them in fresh water and wore them home, where they dried during the trip.
Are they quick-drying or antimicrobial? What features make them stand out?
Yes, the socks are both quick-drying and antimicrobial. Unlike cotton or synthetic materials, Merino wool is naturally antimicrobial and can wick moisture from the skin, storing it in the fibres of the wool. You can even wear the socks multiple times without needing to wash them, which is perfect for an on-the-go surfer or traveller who doesn’t have access to washing facilities.
Did you include any sustainable or eco-conscious materials in the design?
Yes, Merino wool is sustainable. Sheep are shorn annually, which benefits their well-being and supports land management. Even if the sheep are raised for the meat industry, the herculean wool we use underfoot in our socks is typically repurposed from an oversupply that often ends up in landfills, giving it a second life. Furthermore, all Nuyarn / Herculan wool is sourced responsibly from farmers certified by the Responsible Wool Standard.
Are they meant for wearing post-surf, during travel, or even while surfing?
The socks are generally designed to be worn before and after surfing. However, due to their split-toe design, they can also be worn with surf booties, which also makes them compatible with sandals or thongs. Additionally, the socks are great for travel; as explained above, they can be worn multiple times without washing due to their thermoregulation and natural antimicrobial properties.
How do they perform in hot, tropical climates versus colder beach spots?
While I haven’t yet personally tested them in tropical climates, I did test them during the summer in New Zealand. The socks have been my go-to. They keep my feet cool, wick away moisture, are odour-resistant, and provide good ventilation. The socks also perform just as well in winter with the same attributes explained above, and they keep your feet warm due to their thermoregulation properties.
What problems do these socks solve that other performance or travel socks don’t?
The ergonomic construction of the left and right foot, seamless split-toe design, placement of durable wool in high-abrasion areas, elastic arch support, and strategically positioned breathable mesh panels atop the foot ensure superior functionality compared to other performance socks on the market. These socks can be worn in summer or winter and alone, with thongs, or with shoes. Additionally, another significant problem that our FCS socks address is their durability and lifespan. The Nuyarn has been independently tested and can last 8.8 times longer than traditional wool socks, meaning they can endure nearly nine times longer than other performance travel socks.
What was the biggest challenge in developing them?
The biggest challenge was getting the 3D knitting machine to join the split toe. Regular split-toe socks have seams around the toes, while our socks are constructed using seamless 3D knitting. It took countless prototypes and the technician reprogramming the machines before we could finally join the toe area effectively. I spent considerable time with the technician at the sock factory to ensure that all the sock features were positioned correctly and were the right size. For instance, elastic arch support bars are placed in the arch and must be positioned accurately. The placement of Herculan wool on the bottom and top of the foot adds durability and abrasion resistance when wearing the sock with thongs or sandals. Mesh panels on top of the foot sit behind the thong or sandal straps for enhanced breathability, and flexible panels ensure an ergonomic fit. Lastly, as more of an aesthetic and brand feature, we spent significant time ensuring that the FCS logo and fonts on the sock appeared correct. We had to reprogram the machine many times to ensure that the logo followed our FCS logo despite ‘distortion’ due to stretch.
Ultimately, we achieved our goal and ended up with a truly unique, high-performance, fit-for-purpose travel and surf sock.
