The tri-suit development is part of a global Swiss Side textiles R&D project which also encompassed the AERO Calf Sleeves and AERO Socks developments.

Using the results and fabric selection from the Swiss Side wind tunnel test, multiple suit prototypes were developed with different fabric and suit structures. The most promising aerodynamic fabrics were tested on the legs, body sides, shoulders, and arms. A total of more than 15 different prototypes were tested in the wind tunnel on the full-sized mannequin.

The final tri suit prototype was tested against 3 other suits to validate its aerodynamic performance. Two of the typically best performing suits on the market, and a main brand top tier suit were tested. The AERO Tri Suit is the best of the tested suit at 35 and 45 km/h and the second best at 55 km/h.