REV’IT! Tailortech: Precision in Custom Suit Production

Tradition Meets Innovation in the Service of Racing Performance

Made‑to‑measure production, tight delivery schedules, and uncompromising quality standards: for REV’IT! Tailortech—the REV’IT! Sport International division dedicated to custom motorcycle gear—automating the cutting process was a strategic milestone.

Established in January 2024 following the acquisition of long‑time partner Vircos, a company with more than 40 years of expertise, REV’IT! Tailortech produces tailor‑made suits for both professional racers and passionate riders. The partnership between the two companies dates back to 2007, when Vircos created the very first REV’IT! suit for MotoGP.

Operating within the fast‑paced, deadline‑driven world of international racing means two things are non‑negotiable: absolute product quality and flawless delivery timing.

REV'IT! (11) — Design and performance excellence: every detail of each suit is engineered to meet the highest standards in motorsport.

The Challenge: Flexibility and Extreme Precision for One‑Off Production

Every suit is a one‑of‑a‑kind product, fully customized. This production model demands:

maximum operational flexibility
absolute precision on technical materials and logos
fast, reliable turnaround times

Adding to this: the increasing difficulty of finding skilled specialists for manual leather cutting—an intensive and hard‑to‑scale craft.

REV'IT! (2) — The Zünd G3 Cutter in operation at REV’IT! Tailortech.

The Solution: Zünd G3 Cutter for Highly Variable, High‑Precision Production

REV’IT! Tailortech chose Zünd technology for its ability to handle single‑piece production with exceptional accuracy and rapid job changeovers.

With the Zünd G3 Cutter, the team now cuts every material used in a suit:

cowhide and kangaroo leather
linings and stretch fabrics (lycra)
Kevlar® inserts and high‑resistance technical textiles
foams, hook‑and‑loop fasteners, and accessory components
printed logos on eco‑leather

The system ensures flawless contours and consistent quality—eliminating the inaccuracies typical of manual cutting.

REV'IT! (4) — Nesting e taglio di precisione su pelle, lycra, schiume, velcro, kevlar e materiali tecnici ad alta resistenza.

“What we appreciated most about Zünd is their customer‑focused mindset. They really stepped into our shoes—literally—and that made all the difference.”

Iacopo Forte

Managing Director, REV’IT! TAILORTECH

More Efficient Processes and Better Use of Floor Space

Before automation, cutting took place in two separate areas, with split orders and longer lead times. Introducing the Zünd G3 made it possible to:

consolidate all cutting into a single area
simplify and shorten production flow
reclaim valuable floor space
improve order management and organization

At the same time, automation reduced physically demanding tasks, improving working conditions for operators.

REV'IT! (7) — Processi ottimizzati e maggiore controllo qualità grazie all’integrazione tra automazione e competenza artigianale.

Results: Superior Quality and Greater Process Control

Thanks to Zünd technology, REV’IT! Tailortech achieved:

extremely high cutting precision
superior functional and aesthetic quality
increased operational efficiency
faster, more streamlined workflows
optimized use of production space

This investment supports a high‑performance, fully custom manufacturing model—fully aligned with REV’IT! Tailortech’s commitment to design, performance, and innovation.

A Production Revolution

The Manufacturing Breakthrough at REV’IT! Tailortech

Watch the video to discover how REV’IT! Tailortech transformed its production workflow with the Zünd G3 Cutter — from handling highly variable single‑piece orders to reducing material waste, and from boosting quality to enhancing operational control: A concrete example of innovation powering performance.