Inside Wind Tunnel Testing | Marginal Gains & the Giro d’Italia Race Kit

Join us as we dive into the cutting-edge world of aerodynamic cycling apparel with Steve Smith, Castelli Brand Manager, Lifelong Marginal Gainer. From the evolution of the iconic maglia rosa for the Giro d’Italia to the latest innovative firsts, Steve shares how rider feedback, wind tunnel testing, and meticulous design come together to create high-performance gear. We explore the behind-the-scenes logistics of outfitting pro teams, the development process inside Castelli’s Speed Shop and Pro Shop, and how amateur cyclists can benefit from the same technology. Tune in for a look at where aero clothing is headed—and Castelli’s role in shaping its future. CHAPTERS 00:00 Intro 04:40 Amount of Clothing Supplied to Giro Race Leaders 12:24 Sanremo 8S Speed Suit 14:03 Tailoring Suits for Performance and Fit 16:25 Optimized Gear for Specific Rider Positioning 19:53 Low-Hanging Fruit for Maximum Performance 23:30 Free Aero S Bibshorts 28:08 Free Aero Prototype Testing 31:54 PoliMI Wind Tunnel – Politecnico di Milano 33:55 Custom Program, Speed Shop, and Pro Shop 36:42 Aero Race 8S Jersey: Design and Functionality 41:42 Aero Gains: Performance Comparisons 47:08 Future Frontiers in Aero Clothing 53:13 Giro d'Italia, Stage 15, Passing by Castelli HQ 55:09 WIN a Singed Maglia Rosa! 55:41 Ending LINKS Castelli Speed Shop https://www.castelli-cycling.com/Spee... Castelli Pro Shop https://www.castelli-cycling.com/PRO-... – GUEST – Meet Steve Smith: Castelli’s Brand Manager & Lifelong Marginal Gainer! From racing bikes in Portland to leading innovation at Castelli, Steve Smith brings a deep passion for performance. In this episode, he shares insights on wind tunnel testing and the game-changing gear behind the Giro d’Italia leaders. Dive into the tech, the strategy, and the gear that keeps the pros ahead. CONNECT   / smittystuff   #castellicycling #podcast #cyclingpodcast #aerodynamics #aero #roadcycling