16 iterations and countless hours in a wind tunnel, how MAAP developed the jersey that Luke Plapp didn't want to take off

The new MAAP Pro Aero jersey has been worn by Jayco AlUla riders for most of the year, notching up multiple WorldTour wins, including stage wins at the Tour de France and Giro d’Italia. MAAP has now shared information on what they think makes this piece of kit so special – the fabric. So what's all the fuss about and is it a contender for the best cycling jersey crown?

The AARTERO Flyte proprietary aero fabric was put through a relentless testing regime, using Luke Plapp as the guinea pig. The aerodynamic gains stem from commonly used 3D-ribbed sleeve channels that smooth turbulent airflow and reduce air separation across the arms and shoulders, two areas known to impact aerodynamics. Testing showed Plapp could save 6–8 watts over 100km, which equates to 60-seconds.

All kit that goes into a wind tunnel is tested across a range of wind speeds and yaw angles, often landing on a design that best suits their need. MAAP, however, claims its hit the jackpot. “Other manufacturers design kits that work at certain speeds, which deteriorate when out of that specific speed band," Plapp said. "The MAAP Aero Jersey works well across all speeds."

"I spent more time in the tunnel than anyone else, but all the riders in the team wear the new Pro Aero Jersey in virtually every race we participated in this year. Even on the cold days, we would put thermal base layers on to ensure we could still have this fabric as the outermost layer."

Before the final iteration was approved for use, sixteen prototypes were created, tested, and refined – focusing on fit, comfort, and thermoregulation. The result culminated in an ultra-thin 20-micron fibre matrix construction weighing 100 g/m². Long-term durability was also a focus for this project, and the Jacquard weaving is claimed to be resilient to degradation, delamination, and abrasion.

“We have a lot of kit to use throughout the season, but I trained with the Aero Pro jersey and race suit and have done close to 30,000-40,000 km this year between seven kits – and that’s got me through the whole season,” said Plapp.

The jersey was developed to work as an individual garment with no need for a baselayer with 'trips' sewn in to improve aerodynamics. "From the testing we did, there were no gains found in wearing 'trips' under the Pro Aero Jersey," said Plapp. "It seems that you can either use trips on the outer fabric or use a simple plain fabric on the outer and trips underneath to achieve similar results. But that has implications when it comes to thermoregulation."

The Aero Pro jersey is incredibly stretchy – almost mesh-like in design, so it fits snugly. As per traditional cycling jersey design, there are three pockets on the back, which can be used to hold anything from tools to bars without issue.

The Jayco AlUla team uses a base range of sizes and have customised fitting sessions – Plapp, for example, added 2cm to his sleeves and a bit of length to his legs. The general consumer won’t be able to tweak these elements, but the fit remains form-hugging and comfortable.

Moving forward, MAAP will also be adding a top-to-bottom Pro Aero speeduit using the same AARTERO Flyte fabric. In terms of ancillary kit, there will be a direct correlation in speed technology across all fabric touch points from the gloves and socks through to the sleeves.