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Materials Engineering

Flow Control / Smart Materials:  Characteristics like texture, porosity, permeability, diffusion, resistance, and resilience are evaluated for wind noise reduction effectiveness across a range of wind speeds and turbulence levels.  In this regard, we are the only cycling-associated company to hold a wind noise reduction utility patent (9,078,482).

 

Material considerations include:

  • Comfort:  Heat and perspiration transfer + hypoallergenic.

  • Acoustics:  Ambient sound transmission (i.e. transparency).

  • Durability:  Construction, chemical resistance, and washable.

Effectiveness is our first priority.  It would be easy to make a product that looks like it works or make exaggerated technology and performance claims.  That's not who we are.  Our goal is to engineer wind noise reduction products that meet or exceed customer expectations.  Cat-Ears / AirStreamz are the highest rated WNR products of their kind.

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Smart Flow Control:  Understanding the influence of permeability and thickness on flow behavior.  Allowing some wind to flow through in a controlled manner ~ less overall turbulence and moisture (sweat) reduction opportunities.

Acrylic Fibers

Acrylic fibers form a compliant, high-loft porous layer that interacts directly with the incoming turbulent boundary layer.  As air passes through the fiber matrix, velocity gradients are redistributed, and small-scale eddies are broken down through viscous dissipation.  This reduces the amplitude of near-field pressure fluctuations (hydrodynamic pseudo-sound) convecting past the ear.  The result is a measurable attenuation of broadband wind noise, particularly in the low- to mid-frequency range where turbulent energy is most dominant.

Polyester Fibers 

Polyester fibers provide a more structurally stable porous medium that governs bulk flow resistance and permeability.  By partially allowing flow-through, the material modifies the local pressure field and weakens shear-layer development near the ear - functionally similar to a base-bleed effect.  This reduces large-scale coherent structures and stabilizes the wake region, leading to lower turbulence intensity and diminished pressure fluctuations.  The outcome is a smoother, more controlled flow field and reduced wind noise across a wide range of cycling speeds.

Simply Stated

Acrylic behaves like a soft, lossy turbulence absorber - very effective at damping wind noise, especially at lower speeds and larger eddy scales, and Polyester behaves like a flow-conditioning medium - it manages airflow rather than aggressively dissipating it.

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Legacy Material Testing

Our original testing followed Edison's approach when he developed the first practical light bulb.  We road-tested different designs and materials until we discovered the unique effectiveness of porous pile fabrics.  We eventually tested about 75 different pile variations prior to the introduction of our 2012 products.

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Pile Material Supplier

Our material supplier has "an in-house research and development team to create a media to meet customer requirements.  The technical team has the ability to control fiber and yarn selection, pile height, density, tensile strength, width, color, and stitch count.  This allows customers to develop performance fabrics for diverse and unique fabric applications." - MM

Aero-acoustic engineering helps us develop the most effective products.

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