Aerodynamic testing mannequins: Make It Move (2026)
Ross Stevens
The first generation of athlete replicas has already changed the rhythm of performance research. Instead of waiting for exhausted cyclists to sit through hours of wind tunnel testing, technicians now rely on precise, durable 3D-printed mannequins – faithful physical doubles built from detailed scans. These static forms capture posture, equipment interaction, and aerodynamic profiles with remarkable accuracy.
But something is still missing.
Air does not move the same way around a still body as it does around one in motion. Subtle shifts – the angle of a knee at the top of a pedal stroke, the tilt of a neck under strain – change drag in ways that static testing cannot capture. The mannequins are precise, but they are frozen in time.
This research project in collaboration with University of Auckland (UoA) and their wind tunnel facility and Cycling New Zealand (CNZ) sets out to change that: Make It Move.
Building on earlier work, the team turns to an open-source cyclist model originally developed by Delft University. It is a solid starting point: anatomically consistent, already proven in aerodynamic studies. But in its current form, it remains rigid and unmoving, limited to snapshots rather than sequences.
The redesign begins in CAD.
Ross Stevens carefully dissected the digital model, introducing articulation at key points: the neck, the waist, and the knees. These are not arbitrary choices. Each joint represents a critical variable in cycling aerodynamics, where even a few degrees of movement influence airflow separation and turbulence. The challenge is not only to allow movement, but to control it with precision and repeatability.
The solution is both mechanical and elegant.
A driven rear wheel becomes the force of the system. As it turns, it powers the legs through a continuous pedaling motion, transforming the mannequin from a static object into a dynamic participant in the wind tunnel. The motion is smooth, consistent, and—most importantly—measurable.
At the upper end of the body, the neck requires a different approach. Here, Ross designed a bespoke ball joint system, allowing fine adjustments to head position. This enables researchers to simulate subtle posture changes: a rider lowering their head to reduce drag, or lifting it slightly to improve visibility—each variation captured and analyzed in real time.
What emerges is something entirely new: not just a physical replica, but a controllable system capable of 4D analysis—three-dimensional form evolving through time.
For the researchers, Make It Move is more than an upgrade. It is a shift in perspective.
The mannequins are no longer just stand-ins for athletes—they become tools to explore movement itself.
This research project has been supported by University of Auckland (UoA), Cycling New Zealand (CNZ), the MADE group at Victoria University of Wellington Te Herenga Waka and NZ Product Accelerator (NZPA).
Advisors: Michael Kingan (UoA) and Timothy Crouch (CNZ)
Software
Prusa slicer
Hardware
The 3D Printery large-scale FDM printer
Project Level:
Academic Research