Wind Tunnel Research
Performance and innovation in cycling technology are at the core of everything we do at Kalas. Our relentless focus on research and development, combined with cutting-edge material technology, enables us to create world-class custom cycling clothing engineered for speed. Working closely with our partners, we deliver the highest level of support - helping them claim World Tour victories and gold medals. From designs wind tunnel-tested at the iconic Silverstone facility to advanced aerodynamics fabrics, every Kalas product is crafted to give athletes a decisive competitive edge.
In 2022 Kalas Sportswear and advanced technology brand Vorteq embarked upon a groundbreaking research and development partnership with the aim of creating the world’s fastest racing pro cycling. Together we have identified maximal gains using Vorteq’s patented double-layer technology. The result is the Kalas PROJECT Collection.
Made by Kalas, validated by Vorteq.
Test Methodology
All data published here was collected from tests at the Silverstone Sports Engineering Hub wind tunnel during 2024 and independently validated by Vorteq engineers. Tests were conducted using a static mannequin equivalent to a Kalas standard size 3. We tested in both the aero time trial position and the classic road race position ‘on the drops’.
The quality and volume of data we have been able to analyse together is exceptional. We have already used this data to find considerable gains for our customers, including Alpecin-Deceuninck who benefitted from this partnership with time in the Silverstone wind tunnel where we optimised their skinsuits for the Tour de France.
The tests were conducted at various wind speeds from 40 to 70 km/h in 5–10 km/h increments and at various angles from -8 to +8 to accurately reflect the different race conditions. Our PROJECT Collection was tested against what were previously our top performing garments. The Brios skinsuit for example was worn during Tour de France stage and Monument victories. We can now demonstrate the kind of gains you might experience when you, for example, upgrade your Brios to PROJECT RR, or Sonic to PROJECT TT, wear the PROJECT 01 Undersleeve with your Razor jersey, or add some aero accessories.
Some general themes that emerged from our tests:
- Wearing a badly fitting skinsuit can cost in the region of 1–3% CdA
- PROJECT RR Skinsuit saves 1.5-4 % CdA compared to Brios Skinsuit
- PROJECT RR Skinsuit saves 2.5-8 % CdA compared to Razor jersey
- PROJECT TT Skinsuit saves 4–6% CdA compared to Sonic Skinsuit
- Wearing PROJECT aero socks or overshoes can save 3–5% CdA versus
regular shoe/sock combinations
The PROJECT Collection
We launched the PROJECT RR (Road Race) skinsuit together with the PROJECT TT (Time Trial) skinsuit. Specialist track skinsuits TE (Track Endurance), TS (Track Sprint) and TO (Track Omnium) were added to the collection shortly afterwards. Since then, we have added aerodynamic socks, overshoes and undersleeves to our PROJECT Collection.
All these wind resistance-defying garments are developed using the same principles behind Vorteq’s patented double-layer technology and were worn by members of the Great Britain Cycling Team during their record-breaking medal haul at 2023 UCI Cycling World Championships in Glasgow. Since then it has been used in all major races.
"The PROJECT Collection represents our commitment to bringing Olympic-level innovation to riders everywhere. Through meticulous testing, cutting-edge design, and a relentless focus on performance, we have created products that offer professional-level benefits while remaining accessible and affordable."
"This is just the beginning. Innovation is at the heart of everything we do, and we are dedicated to pushing boundaries even further. Our goal is to continue refining our products, exploring new materials, and advancing technologies to meet the evolving needs of every rider —whether they’re chasing their next podium or their next personal best."
František Klouček
R&D Director
Real World Results
The PROJECT RR 1.0 is the main weapon of choice for Alpecin-Deceuninck in their quest for Monument victories and Grand Tour stage wins. Jasper Philipsen has repeated multiple stage wins in the Tour de France in 2022, 2023 and 2024. He was also victorious in a tight bunch sprint in Milan-San Remo 2024.
In 2023 Mathieu van der Poel also raced to victory in Milan-San Remo before taking
a memorable ‘one-two’ with teammate Jasper Philipsen in Paris-Roubaix, setting a then
fastest ever average speed for the race (46.8 km/h over 256.6 km).
In 2024 Mathieu won the Tour of Flanders, before he and Jasper repeated their ‘one-two’ in Paris-Roubaix. This time Mathieu soloed the final 60 km, his PROJECT RR skinsuit the only thing to
protect him from the wind. He set a record average speed (47.8 km/h over 259.7 km) for the second consecutive year.
Realise your own maximal gains
Using authentic wind tunnel test data, independently validated by Vorteq engineers, and with reference to real world performance examples, we demonstrate the gains you can make by using these garments rather than more traditional kit options like regular jerseys and bib shorts.
Get more information about our PROJECT Collection in our AeroBook