Discover Polartec® AirCore™ — the revolutionary fabric that’s lightweight, breathable, PFAS-free, and made from recycled materials, designed to keep you dry from the inside out.
Watch interview on YouTube:
https://youtu.be/-EFOAr534V4
As the industry’s first advanced air-permeable laminate, AirCore™ combines stretch, windproofing, and water repellency with nanofiber technology that actively vents sweat without sacrificing protection from the elements.
In this episode, Ramesh Kesh, Senior Vice President at Milliken & Company and Business Manager at Polartec, joins Steve Smith, Castelli Brand Manager, to share how this breakthrough came to life, and why it could redefine winter cycling gear for years to come.
Together, they unpack the science, the challenges, and why Castelli’s new winter collection — launching September 9, 2025 — marks a turning point in performance cycling apparel. From lab testing to real-world rides, discover why AirCore™ is set to become the new benchmark in cycling performance.
– LINKS –
Castelli
www.castelli-cycling.com/polartec-aircore
https://www.castelli-cycling.com/II/en/custom/full
Polartec®:
www.polartec.com/fabrics/weather-protection/aircore
– GUESTS –
Ramesh Kesh
https://www.linkedin.com/in/rameshkesh
Steve Smith
www.instagram.com/smittystuff/
CHAPTERS
00:00 Intro
03:56 Quick-Fire Round
07:16 Why New Fabric Was Needed
13:26 Engineering Breathability
19:41 Inside the AirCore™ Fabric
25:20 How Movement Activates Performance
28:03 Removing PFAS chemicals,
30:33 Real-World Performance
33:26 Breathability & Numbers
37:50 Waterproofness & Water Column Explained
40:04 Soudal Quick-Step
41:27 Product Collection
45:52 Sustainability & The Future
49:03 AirCore Setting a New Standard
52:11 Looking Ahead
52:54 Sum up AirCore
53:36 Outro
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