MAS Technology: How Fusion Built a Zonal Aerodynamic System Launched at Kona 2026
Watch the full episode on YouTube:
https://youtu.be/XcZWEwV-4LA?si=ZC-YR65RxDXrAiZ7
Tri-Oraklet talks with Johannes and Sebastian from the Tempo_Tech Windtunnel and Fusion about MAS (Multi-directional Air Shaped) technology, launched at the Ironman World Championship in Kona. They cover how a 3D surface structure woven into fabric moves beyond stripes and ribs, and how it was tested in the tunnel and in the field.
Key topics
Origins: Development began around the 2022 Ironman World Championships with wind tunnel fabric mapping. Fusion's in-house Tempo wind tunnel has run for two years.
Beyond stripes: Earlier suits relied on stripes or ribs. MAS uses a 3D surface structure that works across a wider speed bracket and more angles of attack.
Drag2Zero and Simon Smart: The structure was originally devised by Drag2Zero and Simon Smart as a 3D-printed silicone structure. Fusion wove it into fabric using a super fine construction technique and full supply chain control.
Normann Stadler: The Kona winner and 2006 Ironman record holder tested in the tunnel before racing the age-group Ironman in a Fusion suit.
Zonal design: Different fabrics are used on the sleeves, shoulders, back and side panels, with a smooth front.
Drag curve: The effect starts around 30 km/h and is fully present around 45 km/h.
Back zipper and ice pocket: The new ice pocket has neck channels. Magnus Ditlev used it in Kona.
Testing: Seven Kona athletes spent up to almost 300 hours in the tunnel. Final testing took place in France with Sam Laidlow. Field testing used an aerosensor (pitot tube) to calculate CdA.
Protection: The technology is patent-protected, with exclusive fabric manufacturing. It will be applied beyond triathlon.
Three key takeaways (from Johannes)
Multidirectional versatility across the speed range and angles of attack.
The zonal approach.
A holistic rider-bike system view that includes swimming, running and cooling with the ice pocket.
Chapters
0:00 - Cold open: MAS as a system approach to aerodynamics
0:39 - Welcome and introduction of guests
0:59 - From idea to Kona debut; origins in 2022 and fabric mapping
4:09 - Why change a winning formula: the Tempo wind tunnel
5:12 - What MAS stands for and moving beyond stripes
7:08 - A holistic, zonal system
8:38 - From 3D-printed silicone to woven fabric (Drag2Zero and Simon Smart)
10:18 - The story of Simon Smart and the Fusion Tempo wind tunnel
11:51 - Testing Normann Stadler twenty years on
16:44 - Where the fabric and suit are made
17:27 - Developing with athletes
19:36 - Almost 300 hours of tunnel testing and final testing in France with Sam Laidlow
22:03 - Field testing with the aerosensor
24:47 - Suit features: fabrics by zone
26:07 - The smooth drag curve (starts around 30 km/h, full effect around 45 km/h)
28:08 - Side panel and back structure
30:01 - Back zipper and the new ice pocket (used by Magnus Ditlev in Kona)
32:42 - How big a leap is MAS?
34:02 - Patents, design protection and exclusive fabric collaboration
35:43 - Why this came from Fusion and triathlon
37:09 - Aerodynamics as an endless puzzle
38:48 - Working with the best athletes in the world
40:28 - Three key takeaways
42:24 - Where to learn more
Where to learn more
Fusion's website has a MAS technology landing page and product pages for the suit and calf sleeve. The Blueprint white paper includes the data collection. Fusion's channels are also mentioned.
