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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