Know-how
Compression in sports – everything you need to know
Part 2: Production with Product Manager Moritz Rahn
In part one of "Compression in sports", Dr. Casper Grim showed how targeted compression can support top athletic performance through improved blood circulation, enhanced stability, and faster recovery. In part 2, the focus is now on the production of these high-performance products. Bauerfeind Sports Product Manager Moritz Rahn gives us a detailed insight into the processes and special features involved in the development and manufacturing of compression products.
Questions and Table of Contents
- Can you briefly introduce yourself and tell us a bit about your background?
- What exactly do you do as a product manager at Bauerfeind Sports?
- And what about your personal involvement in sports? Do you also use Bauerfeind Sports products yourself?
- How does a product development process start at Bauerfeind Sports?
- And who decides in the end which topics from the pool are implemented?
- How long does such a development process take?
- What role do material selection and fit play in this context?
- How are prototypes tested and optimized during the development cycle?
- What role does design play in the production process?
- How do you differentiate between medical and sports use in design?
- What special manufacturing techniques are used for compression products and how do they differ?
- What needs special attention in the production process?
- Finally: What trends and challenges do you currently see in the industry?
Hi Moritz, thanks for taking the time to talk to us again today. Can you briefly introduce yourself and tell us something about your background?
Moritz Rahn: Sure. I'm Moritz Rahn, Product Manager at Bauerfeind Sports. I completed my first degree in Eisenach and then studied Sports Management and Economics in Jena. During my studies, I did an internship at Bauerfeind. After that, I worked here as a student trainee and wrote my bachelor’s thesis at Bauerfeind Sports. That ultimately paved the way for my current position.
Our compression products for you
Moritz Rahn: My job is basically divided into two areas: on the one hand, I’m active in project management and focus on developing new products. On the other hand, I take care of our existing products and ensure they are always up to date.
“Not all compression products are the same. There are huge differences depending on where and how pressure is exerted on the tissue.”
And what about your personal sports activities? Do you also use Bauerfeind Sports products yourself?
Moritz Rahn: Definitely! I’m very active in different sports. I play handball, go running, ride my racing bike and also play tennis. For all these sports I really use almost all of the Bauerfeind Sports products. The two I wear the most are the Sports Knee Support, because it always gives me great support, and the Outdoor Merino Socks, because I can wear them all year round for any kind of activity.
Let’s dive deeper into product development and technology. How does product development actually begin at Bauerfeind Sports?
Moritz Rahn: The development process usually starts by identifying a need from athletes. Then we carry out intensive market research and analysis. Our team mainly consists of sport-enthusiastic colleagues who also contribute their own experiences and observations. This approach is complemented by current studies and trend analyses. Other departments support us with scientific data and evaluations, allowing us to differentiate between different demands – like running versus hiking, which already have different material requirements (natural vs. synthetic fibers).
And who decides in the end which of these topics are actually implemented?
Moritz Rahn: It’s always a team decision, based on the many different insights. We try to respond to the current and specific needs of athletes – which isn’t always easy. But we also look beyond the obvious and venture into niche areas.
How long does such a development process take?
Moritz Rahn: That varies greatly depending on the product’s complexity. The more functional elements are needed, the longer it takes – usually between six and 24 months.
What role do material selection and fit play in this context?
Moritz Rahn: Both are essential. The material is chosen based on the sport and target group. Runners have different needs than team sport athletes who deal with more physical contact. Our many years of experience and comprehensive measurement data help us determine the fit precisely and adapt it as needed. Compression products can only work properly if they fit perfectly.
How are prototypes tested and optimized during the development cycle?
Moritz Rahn: We carry out various tests throughout the entire process. In addition to quality testing, wear tests are the most important part of development. The closer a product gets to production maturity, the larger the test groups become. In the end, dozens of people test the products – including professional athletes and experts like members of the German Ski Instructor Association or the Hahner Twins during the development of our Trail Run Sock.
Let’s talk about design and innovation. What role does design play in the production process?
Moritz Rahn: Our general philosophy is: "Form follows function." Functionality comes first. Still, design plays an important role – it visually supports the function and gives our products a stylish lifestyle look, without making them appear like fashion accessories. We work closely with renowned designers who give us valuable input, even if not every idea can be implemented right away.
And how do you differentiate between medical and sports use in terms of design?
Moritz Rahn: We offer both medical and non-medical products. As mentioned, we try to visually represent the function through the design. So our supports are designed to visually communicate stability, while our socks focus more on performance. But we still aim to ensure that all products speak the same design language and clearly belong to the same portfolio.
What special manufacturing techniques are there for compression products and how do they differ?
Moritz Rahn: Basically, we distinguish between flat knit and circular knit. Supports that require an anatomical shape are usually flat-knitted, while circular-knit supports are seamless. Socks and sleeves are made exclusively using circular knitting.
What needs special attention in the production process?
Moritz Rahn: Three factors are key: the quality of raw materials, the care of the staff, and the fine-tuning of the machinery – in short: people, machines, and materials. If one of these doesn’t meet the standard, the overall quality suffers. That’s why we rely on continuous quality control.
Finally: What trends and challenges do you currently see in the industry?
Moritz Rahn: A clear trend is product individualization, especially in professional sports. We achieve that with a highly detailed sizing system. At the same time, sustainability is a big challenge and opportunity. We already meet many criteria, for example through durable quality materials and “Made in Germany.” But we’re constantly working on improving and becoming even more sustainable.
Thank you for this detailed insight, Moritz. It’s impressive to see how much expertise and attention to detail go into developing your compression products.
In the third and final part of our "Compression in Sports" series, we’ll head into practice and talk to professional runner Hendrik Pfeiffer. We want to find out what advantages professional athletes see in compression products.
