Nike has introduced its first-ever 3D printed performance apparel — the FlyWeb sports bra — made from a single-layer thermoplastic material and engineered to redefine comfort, breathability, and support for female athletes.
Set to make its global debut today as Kenya’s Faith Kipyegon attempts to break the 4-minute mile in Paris, the FlyWeb bra represents a milestone in additive manufacturing and athlete-centric design.
Crafted from thermoplastic polyurethane (TPU) using advanced computational techniques, FlyWeb allows for variable density zones — denser in high-support areas, airy where ventilation is key — all without seams, straps, or padding.
“It disappears on your body yet somehow delivers incredible support,” said Janett Nichol, Nike’s VP of Innovation. “We’ve never heard that before from women testing sports bras.”
Nike’s move marks the company’s first use of 3D printing in clothing, having previously limited the technology to footwear. The FlyWeb material, developed over several years, offers a breathable feel so innovative that wearers reported feeling airflow on their chest while running — a new sensation for most women.
The company accelerated FlyWeb’s development to align with Kipyegon’s “Breaking4” challenge, a feat Nike hopes will mirror the garment’s disruptive potential.
The 3D printing revolution is also reshaping global fashion: from New York Embroidery Studio’s work with Stratasys printers for high-end textile customization, to independent labels like Australia’s Amiss using desktop 3D printers and scanners to produce full collections in-house, cutting production time from weeks to hours.
“FlyWeb is a signal of what’s next,” said Nichol. “We’re unlocking the future of performance design — responsive, seamless, beautiful.”
No additional FlyWeb products have been announced yet, but Nike has confirmed the technology will be central to future innovations.
