Brugnoli, The Lycra Company and Pissei have developed a high-performance cycling fabric containing 89% bio-based materials, combining renewable raw materials with compression, comfort and durability.
Brugnoli, The Lycra Company and Italian cycling apparel specialist Pissei have collaborated on the PaceSetter project, developing high-performance cycling apparel using fabrics containing 89% bio-based materials. The initiative combines bio-based polyamide from Fulgar with Renewable Lycra fibre to explore how renewable raw materials can be incorporated into premium sportswear while maintaining the performance required for competitive cycling.
New Fabric Combines Renewable Fibres
The PaceSetter project has resulted in a cycling kit comprising shorts and a jersey made from fabrics developed by Brugnoli. The shorts feature Br4/E1, the latest development of the company’s patented Br4 technology.
The fabric combines EVO bio-based polyamide from Italian manufacturer Fulgar, derived from castor beans and corn, with Renewable Lycra elastane developed by The Lycra Company. The Renewable Lycra fibre contains 70% bio-derived content sourced from industrial corn.
By combining these fibres, Brugnoli has achieved 89% bio-based content in a technical fabric designed to meet the demanding requirements of competitive cycling.
The project demonstrates an approach to increasing the renewable raw material content of performance apparel while retaining the functional characteristics required for sports applications.
Br4/E1 Builds on Existing Fabric Technology
Br4/E1 builds on Brugnoli’s patented Br4 technology, introduced more than a decade ago to combine high-performance stretch fabrics with a reduced environmental impact.
According to the company, its proprietary dyeing and finishing technology reduces water and energy consumption by 20% compared with conventional production methods.
Brugnoli also reports that the bio-based raw materials offer a reduction of up to 45% in climate change impact compared with conventional fibres. This figure relates to the materials themselves rather than the complete finished garment.
The new fabric is engineered to deliver high compression, muscle support and freedom of movement, alongside improved breathability and odour control. These properties build on Brugnoli’s existing Explosive Technology.
Renewable Lycra Supports Durability
The Renewable Lycra fibre incorporated into Br4/E1 is a bio-based version of Lycra Xtra Life, which is designed to provide enhanced durability and resistance to degradation.
Its inclusion enables the partners to combine renewable material content with the stretch and performance characteristics required in technical cycling apparel.
The collaboration focuses on integrating developments in fibre composition and fabric engineering to address both performance and material-sourcing considerations.
The three companies believe the project demonstrates the potential to increase renewable raw material content in premium sportswear without compromising the technical properties required by professional athletes.
Industry Partners Highlight Performance and Sustainability
Brugnoli CEO Massimiliano Denna said the development builds on the company’s efforts to combine environmental considerations with fabric performance.
“For more than ten years we have worked to live up to our claim of zero compromises between environment and performance,” said Denna.
“With the collaboration of The Lycra Company and its latest innovation, Renewable Lycra fibre, we can now present Br4/E1 and reach a level of bio-based content that a few years ago seemed unthinkable in a high-performance technical fabric, without giving up anything in terms of compression, muscle support and comfort.”
Denna also identified Pissei as a natural partner, noting its experience with Brugnoli’s technologies and its development of cycling apparel for professional competition, including the World Tour.
Ettore Manfrotto, senior strategic account manager for brand and retail at The Lycra Company, highlighted the importance of collaboration across the textile supply chain.
“Brugnoli has consistently shown this spirit, turning new raw materials into fabrics capable of inspiring the most demanding brands,” he said. “Together, we are helping to drive the next generation of increasingly sustainable high-performance apparel.”
Pissei CEO Filippo Quagli said the project aims to translate advances in fibre and fabric technology into practical benefits for cyclists.
“Innovation means turning materials research into a concrete advantage for every cyclist,” said Quagli. “With Br4/E1 and the new renewable Lycra fibre we can combine compression, comfort and freedom of movement with a more conscious choice of raw materials.”
PaceSetter Project Presented at Industry Events
The PaceSetter concept was presented at Performance Days in Munich on October 13–14, 2026, and is being showcased at Functional Fabric Fair in Portland, Oregon, on October 27–28, 2026.
The project brings together fibre development, fabric engineering and sportswear manufacturing to explore the application of bio-based materials in premium cycling apparel.
Through the Br4/E1 fabric, Brugnoli, The Lycra Company and Pissei are demonstrating how renewable fibre content can be incorporated into performance-oriented textile development while addressing the technical requirements of competitive sportswear.