Chapter 04 · Industrial & Production

Video of laser cut during the pre-production stage

Engineered for
the peloton

Every garment is built from a technical brief, not a fashion mood board. Materials are selected for performance at race pace, then refined until they meet luxury tactile standards.

VELOQUE overview

Four Technologies That Define VELOQUE

All four technologies come from the same place: research with more than 100 cyclists. Interviews and shadowing sessions were categorised into recurring patterns, the patterns became design principles, and the principles became construction.

Luxury cycling garments fail when they prioritise aesthetics over biomechanics. VELOQUE's design brief demanded both, solving real performance problems with materials and construction methods that also meet the tactile expectations of luxury apparel.

Derived from research with 100+ cyclists · patterns and principles → technology

Bonded fabric layers of VELOQUE LAYERS TECH: water-repellent outer shell, brushed thermal mid layer and reflective inner face
Innovation 01

LAYERS TECH

Problem

Single-fabric cycling jerseys fail to manage moisture stratification, sweat accumulates at the skin layer, increasing drag and thermal discomfort during long efforts.

Solution

A multi-layer bonded fabric system that separates moisture transport from structural fabric, inner layer wicks, outer layer breathes, structural layer maintains silhouette under aerodynamic load.

System

Every layer is designed to work with the others. Each garment takes the rest of the range as its base, so combinations stay adaptable, compatible and easy to carry on the bike.

Material Engineering
Leg hem of a VELOQUE bib short holding the thigh without a silicone gripper band, embossed V mark on the panel
Innovation 02

SILICONE-FREE CONSTRUCTION

Problem

Standard silicone leg grippers cause pressure marks and skin irritation on long rides, a known pain point for amateur and professional cyclists alike.

Solution

Anatomically cut fabric with a precision-engineered hem geometry replaces silicone entirely. The gripper effect is achieved through compression patterning alone, no foreign material at the leg interface.

Biomechanics Research
Cyclist in a VELOQUE seamless base layer adjusting a glove cuff, showing the continuous knit surface at wrist and sleeve
Innovation 03

SEAMLESS CONSTRUCTION

Problem

Sewn seams create friction points under saddle contact zones and at shoulder-to-sleeve junctions, causing chafe on rides over three hours.

Solution

Critical contact zones use flatlock seamless knit construction. The result is a smooth internal surface at every high-friction point while maintaining structural integrity of the outer silhouette.

Ergonomic Testing
Roland TrueVIS wide-format eco-solvent printer running a printed panel, the machine used for VELOQUE graphics
Innovation 04

ECO-SOLVENT PRINTING (low-impact process)

Problem

Conventional sublimation printing introduces plastisol compounds that stiffen fabric, reduce stretch recovery, and degrade after repeated high-temperature washing cycles.

Solution

Eco-solvent water-based inks applied at low temperature preserve fabric elasticity and stretch recovery across 200+ wash cycles. The print integrates with the knit structure rather than coating it.

Sustainability & Durability

27 Models Across Two Collections

The VELOQUE range is organised into two worlds: Limited Drops, seasonal, numbered pieces with unique colourways, and Essentials, the permanent technical foundation of the wardrobe. Each model undergoes the same construction standard regardless of collection tier.

Scope of the industrial design workstream

27 Total garment models
4 Material innovations
6 SKUs in the first drop
4 Rider personas mapped
Rider testing a VELOQUE jersey on the road, real-condition product testing
Testing our frontier product

The Range

The range is built in two halves, and each half answers a different thing riders told us. Essentials stay permanent and neutral, because that is how a closet is actually used. Limited Drops carry the colour and the new technology, and they arrive in waves.

Every model in it answers a solution developed from user needs surfaced in the research: all of them extracted from the interviews and surveys, then turned into a line, a cut or a colour rule.

Every line traces to a research need · Interviews and surveys, 100+ cyclists

01 / Essentials

The base of the closet.

Research pointed the same way across every persona. Riders want their base pieces in colours that combine with every kit, and most had already bought a coloured piece they could never match. Colour also fades in the sun, and a faded piece leaves the rotation early.

So Essentials is restricted to three options: graphite black, grey and white. It covers the bib shorts and the peripherals, from arm warmers and balaclavas to gloves, overshoes, windbreakers and rain jackets. The bib shorts split into three lines by use: Comfort-Endurance, Balance and High Performance.

02 / Limited Drops

Where colour lives.

Skinsuits and upper-body pieces carry the season. Every drop brings new limited colours and new adaptations, and the technology moves forward with it.

The architecture underneath stays fixed: five jersey and cold-weather lines, Endurance, Gravel-MTB, Aero, Performance and Climber, plus two skinsuit lines, Performance and Aero. The lines hold their identity from drop to drop, so the colour is the variable and the fit is not.

  • VELOQUE Range

    • Essentials Permanent Graphite black · Grey · White

      • Bib shorts

        • Comfort-Endurance The Sages · Engaged

        • Balance Progressives

        • High Performance Enthusiasts

      • Peripherals

        • Arm warmers

        • Balaclavas

        • Gloves

        • Overshoes

        • Windbreakers

        • Rain jackets

    • Limited Drops Per drop New colours each drop

      • Jerseys & tops

        • Endurance The Sages · Engaged

        • Gravel-MTB Progressives

        • Aero Enthusiasts

        • Performance Enthusiasts · Progressives

        • Climber Progressives

      • Skinsuits

        • Performance Enthusiasts

        • Aero Enthusiasts

The complete range. Mono tags name the persona each line was drawn for.

From Prototype to Production

Every garment passed through a structured development pipeline before sampling. Technical decisions were validated against rider feedback at each stage.

Step 01

Technical Brief & Material Selection

Performance requirements documented per garment category. Fabric candidates evaluated against stretch recovery, moisture management, weight, and tactile quality benchmarks.

Step 02

Pattern Engineering

Anatomical patterns developed in collaboration with technical garment engineers. Aerodynamic panel positioning mapped against wind tunnel data from comparable race-cut designs.

Step 03

Prototype Sampling

First samples produced in base fabric. Fit evaluation across three body types. Critical contact zones assessed for pressure distribution and chafe risk.

Step 04

On-Bike Testing

Prototypes worn on rides of 2–6 hours. Thermal regulation, moisture management, and gripper performance evaluated in real conditions across varying temperatures.

Step 05

Print & Colourway Validation

Eco-solvent print application tested across three wash cycles before sign-off. Colourway accuracy validated against Pantone standards and brand book specifications.

Step 06

Production Sign-Off

Final sample approval and production specifications locked. Quality control checkpoints defined for each manufacturing run.

Production Preparation & Tech Packs

The range is currently scaling towards production. The search is for a manufacturer that lets volume grow while holding the construction standard and avoiding unnecessary fabric waste.

Every garment travels with its own technical pack: graded measurements, material references, construction and seam detail, trims, and print placement, documented in work sheets organised by fabric type and handed to the manufacturer as the single source of truth.

Documentation prepared in work sheets by fabric type
Technical work sheets, organised by fabric type

Production Pipeline

VELOQUE is currently in the advanced sampling stage. Manufacturing is sequenced so the Limited Drop validates the construction standard before the permanent range enters production, and the sequence runs as a loop: iteration sits between every stage and closes the circle after the drop.

Stage 01 · Now

Advanced Sampling

Final samples in review across the range. Construction standard, fit and print behaviour confirmed on production fabric before any tooling is committed.

Stage 02 · Ongoing

Iteration

Feedback from the samples and from the riders wearing them is folded back into the patterns and the specs. Fit, seam placement and fabric weights are revised until the standard holds on production fabric.

Stage 03 · Next

First Limited Drop, 6 SKUs

Jersey, bib shorts, socks in two colourways, cap and arm warmers are scheduled for production sign-off as the opening drop.

Stage 04 · Following

Essentials Line

The permanent technical foundation follows in the subsequent manufacturing window, once the drop has validated the production pipeline end to end.

Stage 05 · Ongoing

Iteration for the Next Drop

What the drop teaches, on sizing, on print wear, on which pieces riders reach for first, is documented and carried into the brief for the next collection. The cycle restarts at sampling.

The pipeline is a cycle: every drop returns to sampling with what it learned

Laser-cut yellow technical fabric panels of a VELOQUE jersey pattern laid out on the workshop table
Cut panels, checked against the pattern before assembly
Hands checking the edge and structure of a laser-cut honeycomb technical fabric panel
Edge and structure check on the honeycomb fabric

The café is the club's living room

The coffee stop is where a ride becomes a social event. In cycling culture, and increasingly in society at large, the café has turned into a key social ritual: the place where the group forms, the stories are told and the brand is seen at rest.

That is why VELOQUE allies with specialty producers to launch its own coffee line, and why the range reaches the machine itself: a La Marzocco × VELOQUE edition for the club's cafés and partner venues. Same numbering, same labels, same restraint. The maison is something you live, and the espresso is part of the kit.

What the whole project taught me

Nine months, four disciplines, one maison. These are the lessons that travel beyond VELOQUE.

  1. 01

    Research pays for itself

    Interviews and surveys with 100+ cyclists decided the range, the neutrals, the technologies and the copy. Every later argument was faster because the evidence already existed.

  2. 02

    A brand is a system, not a logo

    Style, voice, palette, packaging and interface only held together once they were written down as one system in Figma. The design system was the brand book made operational.

  3. 03

    Sell belonging, not gear

    Scarcity you can verify, membership you can feel. The club, the numbered pieces and the drops turned a catalogue into a relationship, and that is where luxury lives.

  4. 04

    Design and manufacturing must start together

    Tech packs, laser cutting and sampling exposed what a render never shows. Next time the manufacturer sits at the table from the first sketch.

  5. 05

    Specs make speed

    Precise UX/UI specifications, Figma, Claude Code and our own agent system let a two-person team build like a studio. Precision upstream is what makes velocity downstream.

  6. 06

    A maison is a business

    Margins, production agreements and investment shaped the design as much as the personas did. Reading the whole system, user, business and product, was the real job.

Status

The complete project will be available for sale in a few months.

Brand, range, e-commerce and production pipeline, ready as one package. If you want to talk about it before then, the door is open below.

Full project explored.

Four chapters. One maison. Return to the overview or explore another discipline.

Liked what you saw? Let's talk about it. UX internship · Summer 2027 · open to a conversation