Professional cycling is integrating digital twins and 3D-printed physical replicas to optimize athlete performance, according to current technical trends in the WorldTour. These “clones”—consisting of a physical rider, a data-driven digital simulation, and a precise 3D model—allow teams to test aerodynamics and equipment in virtual environments before applying them to the rider on the road.
Digital Twins: Simulating Performance in Virtual Wind Tunnels
The “digital twin” is a virtual replica of a cyclist that mirrors their exact physical dimensions and biomechanics. According to technical reports from the cycling industry, these models are created using high-resolution 3D body scans and motion capture data. By importing this data into Computational Fluid Dynamics (CFD) software, teams can simulate how air moves around a rider at specific speeds and angles without needing the athlete to spend hours in a physical wind tunnel.
This process allows engineers to make iterative changes to a rider’s position or equipment. For example, a team can virtually adjust the angle of a helmet or the shape of a jersey on the digital twin to find the lowest coefficient of drag. Because the digital twin is a precise mathematical representation of the athlete, the results are highly transferable to the real-world performance of the rider during events like the Tour de France.
3D Printing and Physical Prototyping
Beyond the digital realm, teams are using 3D printing to create physical models of riders. These printed replicas serve as tangible benchmarks for aerodynamic testing. By placing a 3D-printed model of a specific rider in a wind tunnel, technicians can test various component prototypes—such as new handlebar shapes or frame geometries—without the variability introduced by a human athlete who may shift their position or fatigue during a session.
This physical “clone” ensures that the hardware is optimized for the specific morphology of the rider. In a sport where margins of victory are often measured in seconds over thousands of kilometers, the ability to customize equipment to a rider’s exact anatomical profile provides a measurable competitive advantage.
The Integration of Data and Biomechanics
The synergy between the physical rider, the digital twin, and the 3D model creates a feedback loop. Data from wearable sensors and power meters are fed back into the digital twin to refine the simulation. This allows coaching staffs to predict how a rider will perform under specific environmental conditions, such as varying wind directions or altitude changes in the Alps and Pyrenees.
This approach shifts the focus from general aerodynamic standards to athlete-specific optimization. Rather than fitting a rider to a bike, the bike and the aerodynamic strategy are built around the rider’s unique physical “clone.”
Implications for the WorldTour and Future Competition
The adoption of these technologies is becoming a standard requirement for teams competing for general classification titles. The ability to “clone” a rider for testing purposes reduces the physical toll on athletes during the preparation phase and increases the precision of the equipment used in time trials and high-speed descents.
As scanning technology becomes more accessible and CFD software more powerful, the gap between virtual simulation and real-world result continues to shrink. The focus is no longer just on the athlete’s training, but on the engineering of the athlete’s entire interface with the air.
The next major checkpoint for these technologies will be the upcoming season’s spring classics and Grand Tours, where teams will implement the latest iterations of these personalized aerodynamic profiles.
Do you believe the use of digital twins creates an unfair technological gap between the wealthiest teams and the rest of the peloton? Share your thoughts in the comments.
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