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Polartec Powers into the Cycling World

  • Ron 

Ask the average about and its place in , and they’ll generally say answer that they might pull on a fleece jacket after a cool ride, but probably not something they’d wear on the bike. That was always my perception, but after meeting with Polartec at a show in Summer 2025, I learned that there was a lot more to Polartec than fleece. We discussed a lot of technologies ( for a post on our sister site All Outdoors News about that), but the key technologies for cycling were Polartec AirCore and Polartec Ultra

Polartec AirCore™

Driven by the belief that perspiration impacts performance long before precipitation, Polartec® AirCore™ was developed to offer against the elements while allowing vaporized sweat to escape using air and molecular diffusion. Delivering maximum aeration and breathability without sacrificing comfort, range of motion, or durability, Polartec® AirCore™ minimizes the risk of overheating during high aerobic activities or intense physical pursuits in unpredictable conditions. The state-of-the-art technology of AirCore™ leverages air to maintain a dry microclimate by evaporating sweat from the inside-out and promotes evaporative cooling, the only warmth management mechanism that truly matters for an active user.

The membrane is produced by a process called electrospinning where a hydrophobic proprietary polymer is pushed through a hypodermic needle charged at 20,000 volts. Under pressure, it emits a thin jet of microscopic filaments – approximately 100 times smaller than a human hair – which falls like snow to create an incredibly tight membrane that still allows air to permeate it.

The Sportful Fiandre jacket

The harder you work, the harder the fabric works. Motion fuels the ventilation that ultimately carries moisture away from the body. By staying drier and more comfortable users can experience air-powered, permeable, enhanced performance. In our tests, we found that the pieces we were reviewing performed as advertised.

Reflecting Polartec’s steadfast commitment to , Polartec® AirCore™ is made with a recycled face and back, combined with a non-PFAS membrane and layers.

AirCore fabric will become more available over the coming year, but for now, it can be found in the Castelli Perfetto Ros3 jacket as well as garments from Sportful and Montura.

Where the Perfetto Ros3 is more of a shoulder season jacket, excelling in conditions from 39-57° F, the Sportful Fiandre jacket is paired with a more windproof exterior, and as such, is better  suited for winter conditions (23-41° F).

Details are still forthcoming for a product release from Italian outdoor brand Montura.

Polartec PowerStretch™

Polartec® Stretch™ is what the company calls a ‘contouring fabric’. The advanced, dual-surface knit is crafted from super-strong elastic fibers to deliver four-way stretch that retains exceptional shape memory, ensuring that pieces made with the fabric will spring back to their original form after stretching.

 

While several manufacturers are using the fabric, Santini was one of the first to use PowerStretch™ in their Unico jersey. The Unico is a high-performance technical with a unique style that guarantees incredible comfort. It’s also quick drying and offers great breathability. Even better, it is designed to dress both men and women indistinctly while ensuring an optimal fit for anyone who wears it. The triple back pocket lets you store everything you need while an internally positioned silicone grip at the waist prevents the jersey from hiking up during your ride. With certified UPF30+ protection, Unico helps block harmful UV rays, effectively shielding the skin during long days spent riding under the sun.

Polartec® Alpha™ & Power Shield™ Pro

Velocio used a combination of Polartec’s Alpha™ & Power Shield™ Pro to create their new Velocio Alpha Zero Vest. Velocio designed the Alpha Zero Vest to be a complete layering system in one piece of kit. Combining the two fabric technologies allowed the piece to offers maximum protection against the elements. In fact, it may just be the most refined winter riding vest on the market. What’s more, because the Alpha Zero Vest ensures dynamic thermoregulation across a wide range of conditions, it can be worn instead of a jacket on crisp mornings or as an extra barrier against the deep winter cold.

Designed with versatility in mind, the vest is also highly packable, compressing small enough to be easily stored in your kit when not in use. Velocio’s drop bar fit has been refined over a decade of testing, feedback, and revision. The result is a three-dimensional pattern with every stitch and fabric panel carefully positioned to be quiet on the without restricting movement.

Polartec Alpha also makes an appearance in Velocio’s MTB wear. Their Trail Alpha Hoodie pairs Alpha with a rugged, double-weave shell that delivers featherweight insulation with a durable exterior inspired by workwear.

Polartec Alpha Insulation defies logic — it breathes easy, weighs next to nothing, and adds serious warmth. Originally developed for the US Special Forces to effortlessly handle the stop-go conditions of active combat, it’s available in different lightweight compositions and can also be worn as a direct, next-to-skin fabric. By keeping you warm when needed and releasing excess heat during high-exertion activities, it is ideal for outdoor activities. Using a lofted fiber structure with a mesh core, it allows warm air retention when needed and enhanced airflow during movement. This active thermal-management system prevents overheating and keeps you comfortable in unpredictable environments.

Alpha and AirCore also are utilized in the Alpha 150 jacket. More of a winter-focused garment than the Perfetto RoS3, the Alpha 150 is suited for a temperature range of 28°F – 50°F. AirCore™ fabric brings its unmatched breathability paired with a wind and rainproof fabric, while Alpha insulation is utilized on the inside to warmth while enhancing moisture management. The stretchy close-to-body fit means you don’t feel like you have a full winter jacket on. This jacket is ideal for cold, dry days yet can stand up to everything except all-day driving rain, when you’ll probably reach for a rain shell.

More to Come

With at least ten new fabric technologies hitting the market, you’re sure to see Polartec tags hanging off of a lot of new cycling and outdoor gear in the coming year. And very little of it looks like the Polartec fleece that you remember from years past.

 

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