Developing the New OS2 Offshore System

1. Given Gill’s 50-year history, what were the key design inspirations behind the new OS2, particularly considering the legacy of Gill products?

Redeveloping the OS2 Offshore was an incredibly challenging design project. It is such a firm favourite amongst sailors and has a loyal and passionate following, that we had to be really careful not to lose what makes it unique. This was very much a process of refinement, not reinvention.

Speaking to users of the OS2, the multiple pocket options (10 in total across the suit) allow you to securely stash everything you need, including gloves, marine tools and chocolate bars. The other aspect that we carefully protected was the fit of both the jacket and trouser. The Gill ‘comfort factor’ is something that sets us apart when customers try the suit on for the first time. Careful placement of zoned fabrics ensure that soft, thermal fleece is just where you need it, and smooth linings allow you to layer up quickly & efficiently.

We also consider how thermal layers, footwear and even headwear interact with the suit, with our fitting sessions seeing size models fully layered up and ready for a day’s sail!

2. What specific feedback did you receive from professional racers/adventurers during the development process, and how did that influence the final design of the OS2?

The finished designs are the result of an ongoing process of listening and learning from end users. This isn’t a process with a start and an end, we’re constantly collecting feedback – both good and bad.

The design team have access to every product review we receive and actively use these when we’re considering a design update. We also widely consult with our sponsored sailors from everyday cruisers on the adventure of a lifetime, through to Olympians and Ocean racers

As part of this, we travelled to France for a 2-day immersive development meeting with Conrad Colman, who recently completed the 24/25 Vendée Globe. As a veteran of multiple trans-Atlantic and epic Ocean races, Conrad gives us the perspective of the performance sailor and what he would expect from an Offshore suit. Conrad went on to trial early samples of the new OS2 Offshore System during pre-race testing.

We also worked closely with many of our key retailers, especially those who actively sail and already use previous generations of the OS2. Often immersed in busy marinas and harbours, these accounts spend more time speaking to and understanding the needs of the end users, so their input is invaluable.

4. Can you describe the key technology used in the development of the new OS2? How do you test to make sure it is fit for purpose?

Sustainability and reducing our environmental impact is a common theme in all design and development projects. And the new OS2 Offshore takes the lead in demonstrating how all Marine clothing brands should be considering their approach.

Our XPLORE 2-layer outer fabrics, fleece linings, fluorescent fabrics and even the waterproof linings and care labels all feature recycled content from post-consumer materials. We estimate 98% of the total garment, by weight, now features recycled content and the remaining proportion are items such as zippers and reflectives where a recycled option is not currently available – but we’re working on it!

Our XPLORE fabric also features our new SHIELD water repellent technology, a PFAS-free technology that still delivers incredible levels of water repellency.

Despite these fabric innovations, our greatest commitment to sustainability is the durability and longevity of our garments. Each and every fabric is subjected to relentless testing in our own lab before we approve for use – wash tests, abrasion, waterproofness, flexing, aging, saltwater corrosion, wet colour migration, even scuffing with hook Velcro.

That commitment to product quality, durability and performance doesn’t start and end in the Gill Lab. Every single taped seam, on every single OS2 Offshore garment is pressure tested and guaranteed waterproof before it leaves our factory – an incredibly time consuming and expensive process that is unique to Gill.