Smartwool Turns Old Socks Into Dog Beds: A Step Toward Circular Apparel

Introduction

Fashion waste is one of the most persistent environmental problems today, and one small item keeps showing up in large numbers: socks. Worn, mismatched, or just past their prime, socks are often tossed without a second thought—part of the millions of tons of textile waste ending up in landfills every year. Smartwool, the outdoor apparel brand known for its wool socks, is trying something different. Via its Second Cut Project, Smartwool is collecting old socks from any brand and recycling them into K9 Camp Cushions—dog beds stuffed with upcycled sock material. It’s an initiative aimed at cutting textile waste and pushing the company toward a goal of full circularity by 2030.

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The Problem with Socks & Textile Waste

• Socks are among the apparel items most frequently discarded due to holes, mismatches, or wear. Many people don’t know how to recycle them, so they usually end up in the trash. Treehugger+1
• Globally, only a small fraction of clothing gets recycled properly—most textile waste is landfilled or incinerated. Waste360+1
• Socks are small, fibrous, mixed-material items, which makes them hard to process, sort, and recycle. But taken in aggregate, they represent an opportunity: thousands of socks could become the raw material for new products.

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What Smartwool Is Doing: The Second Cut Project

Smartwool’s solution has several components:

1. Sock collection — The project accepts old socks from any brand, not just Smartwool. Clean socks can be dropped off in collection bins at participating retailers, or mailed in via a prepaid return bag when purchasing from Smartwool’s site. PR Newswire+3Fast Company+3Treehugger+3
2. Processing & recycling — Smartwool partners with a company called Material Return, based in North Carolina, to deconstruct the collected socks. They separate fibers, grind them into “shoddy” (a fibrous mass), and then use those fibers in new applications. Some of the recycled sock material becomes fabric, but in the early phase, much of it is used as stuffing for dog beds. Treehugger+1
3. Product launch: K9 Camp Cushion — The first product from this initiative is a dog bed named the Second Cut K9 Camp Cushion. It uses the upcycled sock fill for the interior, paired with a removable, washable exterior made (in many cases) from recycled polyester. Product sizes vary. PR Newswire+2Smartwool+2
4. Goals for circularity — Smartwool aims for 100% circular products by 2030. This means thinking about not just product end-of-life, but designing with disassembly, recyclability, and re-usable material flows in mind. Treehugger+2Fast Company+2

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Outcomes So Far

• Since launching, Smartwool has collected over 90,000 worn or mismatched socks through this program. Waste360+1
• That collection represents more than 12,000 pounds (≈ 5,400 kg) of material diverted from landfills. Waste360+1
• The dog bed product (K9 Camp Cushion) is being sold in multiple sizes and reportedly is available in the holiday season of launch. PR Newswire+1

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Challenges & Considerations

• Quality of recycled materials: Socks come in many materials and blends. Some fibers degrade badly, some resist cleaning, and mixed materials complicate recycling. Getting consistent fiber quality is non-trivial. Treehugger
• Cost & logistics of collection: Collection bins, shipping old socks, sorting & cleaning all add cost. Prepaid return labels help but scale and participation matter. Fast Company+1
• Durability & product performance: Materials repurposed for dog beds must meet comfort, safety, and durability expectations. Also, how quickly do these products degrade, wash out etc.?
• Scaling beyond dog beds: Smartwool’s long-term plan includes turning sock fibers back into yarn for new apparel and accessories. Getting to that point requires significant scale, material quality, and processes that can handle mixed sources. Treehugger+1

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Why It Matters

This project is interesting and impactful for several reasons:

• It addresses “post-consumer waste,” which is often ignored compared to manufacturing waste. Socks are something many people discard easily; this project gives a visible, practical alternative.
• It leverages a partnership (Smartwool + Material Return) that combines brand, infrastructure, and recycling expertise.
• It demonstrates how circular design can start small—stuffing for dog beds—but serve as a stepping stone to more ambitious circular apparel systems.
• From a consumer standpoint, it builds awareness: that socks (and other apparel) need systems for end-of-life and that participation matters.

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FAQs

Q1: Do the socks have to be Smartwool brand?
No. Any brand of clean socks is accepted. Smartwool’s program invites participation regardless of brand. Treehugger+1

Q2: What happens if the sock fibers are low quality or damaged?
They are processed into “shoddy”—a term for reclaimed fibers. Depending on quality, these go into filling (like dog beds) or less structural textile uses. Higher quality fibers may be spun back into yarn over time. Treehugger+1

Q3: Is this program permanent or just limited?
It began with a limited-time collection period (April-May 2021) but includes options for year-round sock recycling via mail when making purchases. The Second Cut Project is intended as an ongoing push toward circularity. Fast Company+1

Q4: How does this help reduce environmental impact?
By diverting textile waste, reducing demand for virgin materials, extending material life, and helping build systems to recycle apparel. Even though a sock seems small, aggregated waste is large. Also, the initiative ties into smart design and material health.

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Conclusion

Smartwool’s Second Cut Project shows that solving fashion’s waste problem doesn’t always require radical technology—sometimes it’s about rethinking how we use what we already have. Old socks might seem trivial, but by collecting, processing, and repurposing them into functional products like dog beds, the project nudges both brand and consumer behavior toward circularity.

If Smartwool can scale this up—to yarn, accessories, all apparel—the project could help shift expectations: not that clothing is disposable, but that it’s part of a loop. And maybe those holes in your socks won’t be waste after all—they’ll be part of something made new.