Engineering Physics & Manufacturing
The Engineering
AT1 suits are not fashion items. They are deceleration and kinetic energy management hardware, engineered by founder Dominic De Leon — a mechanical engineer who races at ASBK level and won the 2025 Unlimited F2 Championship. Here is the physics, the materials science, and the manufacturing process behind every suit we build.
Kinetic Energy Management
In a high-speed crash, the suit functions as a controlled deceleration system managing kinetic energy. The physics is straightforward: the energy that must be dissipated scales with the square of your speed. At 200 km/h, you carry four times the kinetic energy you carry at 100 km/h.
The work done by friction during a slide is governed by the kinetic coefficient of friction between the suit material and the asphalt, the normal force (gravity), and the slide distance. If the coefficient of friction is too high — or if an exposed seam catches on the asphalt — sudden deceleration creates joint-damaging rotational torque.
Our engineering solution: Recessed seam placement away from primary slide zones, and integrated low-friction alloy external sliders at the shoulders, elbows and knees. These maintain a controlled slide, safely dissipating energy across distance rather than dumping it into your joints in a single impact.
3D Configurator
Every AT1 suit starts in our real-time 3D configurator. You see your suit rendered in full 3D — every colour change, every sponsor logo, every custom shape — updating live as you design. What you see in the configurator is exactly what we build. No surprises, no compromises.
The configurator lets you control every panel colour, swap between kangaroo and cowhide leather, add perforation for hot-weather track days, upload sponsor logos in vector format, stamp your name and race number on the suit, and toggle the speed hump, slider package and airbag system. You can even design matching gloves colour-matched to your suit.
Try it: Open the 3D configurator →
Construction & Materials
Leather selection: High-density top-grain cowhide for durability and affordability, or lightweight premium kangaroo hide for reduced weight and high tensile strength. Both are CE-certified for motorcycle race use.
Stitching hardware: Double and triple high-tensile safety stitching embedded in recessed channels to protect threads from direct friction. Exposed seams catch asphalt and create rotational torque — ours are buried in channels where they cannot.
Dynamic mobility: Keprotec Kevlar-based stretch panels at the groin, inner arms and calves, paired with accordion leather joints. The suit moves with you in the tuck position — no skeletal restraint, no circulatory restriction, no armour rotation.
Perforation options: Standard perforation feeds air across the chest and thighs; Full Body perforation maximises airflow for hot-climate track days. Both are laser-cut for precision.
Airbag Expansion Zones
Every AT1 suit is built with engineered universal expansion zones designed for Alpinestars Tech-Air, Helite and AT1 electronic airbag systems. The expansion zones are engineered into the chassis from the first cut — not retrofitted — and deployment is designed not to restrict respiration.
The airbag deploys in milliseconds on impact, protecting the shoulders, back and chest — the three areas most likely to take impact in a crash. The expansion zones accommodate the inflated bladder without splitting seams or restricting the rider's breathing.
If you already own an airbag system, contact us and we will confirm compatibility before you order.
CE-Level Protection
Every AT1 suit is engineered to meet or exceed EN 13595 standards for motorcycle racing apparel. The full CE slider package is included as standard:
- Shoulder sliders — low-friction alloy, replaceable, maintain controlled slide
- Elbow sliders — low-friction alloy, replaceable, dissipate energy across distance
- Knee sliders — replaceable, colour-customisable pucks
- Speed hump — aerodynamic stability at race pace
- Internal armour pockets — precision-engineered to hold CE Level 2 back, chest and hip protectors securely over joints (sold separately)
The slider mounts are reinforced with double-layer leather backing. Armour pockets are tailored to your measurements — no loose joints, no shifting under impact.
Manufacturing Process
Design
You design your suit in the 3D configurator or pick a Signature Series preset. Every colour, logo and detail is locked in.
Measurement
After checkout, you complete our measurement form with 12 key body measurements. A fitting expert is available to guide you.
Cutting
Full hides are cut panel by panel, with grain direction optimised for each zone. High-wear areas get the densest leather.
Stitching
Master craftsmen stitch the suit with double and triple high-tensile stitching in recessed channels. Keprotec, airbag routing and armour pockets built in.
Quality Check
Every seam, slider, zipper and panel is inspected. If it does not meet our standard, it does not ship.
Shipping
Tracked, insured worldwide delivery. Total turnaround: 6-8 weeks manufacturing + 1 week shipping.
Design Your Suit
Put the engineering to work. Open the 3D configurator and build your custom race suit in real time.