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.