Nike’s FlyWeb: A New 3D Printed Material for High-Performance Garments

On June 12, Nike unveiled FlyWeb, a new 3D-printed sportswear material. Faith Kipyegon, three-time Olympic champion and 1,500-meter world record holder, will debut FlyWeb in her attempt to be the first woman to break the 4-minute mile. FlyWeb was created by Nike’s Innovation team after three years of research in materials and computational design. The reason? To address the need for support, lightness and breathability in high-performance events.

3D printing is nothing new at Nike. For some time now, they have been using it especially as a footwear customization tool. This time, they are taking it much further and applying it, for the first time, to bras. In this way, FlyWeb marks the beginning of 3D materials and technology for high-performance sportswear within the brand.

Nike’s new material is made of TPU.

3D Printing in Nike’s New Material

FlyWeb is made from TPU, a polymer with elastic properties that, thanks to extrusion 3D printing, could be molded into a seamless bra. Choosing a bra was no accident. It is a garment that, despite its widespread use, has hardly changed in terms of construction and materials. Through computational design, a 3D pattern was achieved that varies in density and elasticity according to the areas of the body. This allows an exact fit and support in the parts that need it. In addition, its fabric is very thin and offers an unmatched level of breathability. “You can actually feel the air on your chest. Most women have never experienced that while running. We don’t even think about it because it’s just not something we’ve ever expected to feel.” states Janett Nichol, Nike’s Vice President of Innovation.

Kenyan athlete Faith Kipyegon will wear a customized version of the FlyWeb bra during her attempt to become the first woman to run a mile in under 4 minutes. The event is scheduled for June 26 in Paris. The bra is just one of the garments that have been made especially for the athlete and for this event, although it is the only one where 3D printing is applied. The Nike Research Lab research and design team has also designed an aerodynamic suit called Nike Fly Suit and the Nike Victory Elike FK, ultralight running shoes.

Athlete Faith Kipyegon will attempt to become the first woman to run a 4-minute mile and will wear a bra with Nike’s new 3D material.

In this context, the FlyWeb bra plays a key role. Its ability to minimize moisture accumulation and its light weight are features that make it crucial, even in a one-mile race. Beyond the Kipyegon case, FlyWeb opens the door to a new generation of sportswear. Details such as seam elimination, detailed zone design control and on-demand manufacturing are just some of the possibilities. “This is a true unlock, not just for bras but for how we design and build high-performance apparel going forward. It opens the door to entirely new ideas for how athletes experience sport through what they wear,” Janett Nichol said. Learn more about the material HERE.

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*All Photo Credits: Dan Vernon and Sofieke van Bilsen by Nike