Nike makes custom speed suit with 3D printed aerodynamic devices
The suit was designed for English middle-distance runner Keely Hodgkinson
When 24-year-old middle-distance runner Keely Hodgkinson won the 800-meter race at the Athlos track and field meet in London last week she made headlines. Not only for overcoming an injury that had her unable to race for a year, but also because she took to the track (and eventually podium) wearing a cutting-edge speed suit, unlike any we’ve ever seen before. The suit, custom designed by Nike for the runner, is eye catching with its hood, open back, and glinting delta-shaped aerodynamic details embellished on the fabric’s surface.
As it turns out, these aerodynamic details were actually 3D printed onto the surface of the textile and strategically positioned based on Hodgkinson’s running motion with the aim of minimizing turbulence and giving her what ever extra speed possible. Nike has dubbed these clever features “vortex generators” that “generate targeted mini tornadoes, forcing fast-moving air to attach to the slower airstreams training the body rather than separating into a drag-inducing wake.”
The custom speed suit with 3D printed aerodynamic devices was developed at the LeBron James Innovation Center at Nike’s Philip H. Knight Campus in Beaverton, Oregon. There, the innovation team worked with Hodgkinson to deliver a suit that met the athlete’s aesthetic and functional needs. This included a hood with ponytail opening for the runner’s iconic blonde hair, structural slits in the hood for her sunglasses to slot in seamlessly, and a stylish open back.
Notably, the overall pattern has been custom designed to allow the athlete’s maximum stride length without any creasing or bunching. This perfect fit was achieved using 4D design methodology, which not only considers the body’s proportions when it is still, but also when it is in motion. “Our team studied every detail of how Keely moves through space, ensuring the suit works with her stride, her mechanics and her race demands, creating a distraction-free fit that allows her to focus solely on performance,” explained Hannah Amis, Director of Innovation Apparel Product Design at Nike.
Hodgkinson, who has been a Nike athlete since 2019, is an absolute fan of her new custom speed suit. “In this speed kit, I feel fast, free-flowing, comfortable and empowered,” she said. Dan Farron, Vice President of Innovation Apparel Product Design at Nike, added: “As much as we’re designing for peak performance, we’re also designing for pinnacle expression. Keely’s an athlete who’s unafraid to take risks; she’s bold and vivacious. This speed suit is a reflection of who she is. It’s sport and style in equal measure.”
Nike has been at the vanguard of 3D printing for sports equipment and wearables. Last year, we covered how the sportswear giant created a new performance material called FlyWeb made from 3D printed TPU. At the time, Nike showcased this innovative 3D printed textile by making a custom sports bra for Kenyan middle-distance runner Faith Kipyegon. The company has also developed various 3D printed footwear products, including its second-generation 3D printed Air Max 1000 sneakers, made in collaboration with Zellerfeld.
