For decades, Polartec has enhanced the sports and outdoor industries with its innovative, sustainable textile solutions. In fall 2025, they will launch one of their most revolutionary products to date in collaboration with select partners: Polartec® AirCore™. A truly air-permeable shell fabric for high-output activities, it delivers maximum ventilation and breathability without compromising comfort, freedom of movement, or durability.
Maximum ventilation and breathability without compromising comfort, freedom of movement, or durability
Polartec® AirCore™ the outdoor industry’s first ever hydrophobic nanofiber membrane made from a proprietary polymer, sets a new standard for weather-resistant yet breathable non-PFAS laminates. Not only is it highly elastic, water repellent and the latest example of Polartec innovation in the real world, but it’s also the most air-permeable membrane in the industry. Additionally, it contains no PFAS-based chemicals and is designed to keep users dry from the inside out.
Ramesh Kesh, Senior Vice President of Milliken & Company and Business Leader at Polartec, explains:
“Polartec® AirCore™ is a perfect example of our ongoing mission to merge cutting-edge performance with sustainability. Unlike traditional waterproof-breathable membranes that rely solely on moisture vapor diffusion, our advanced air-permeable laminate uses a highly engineered nanofiber membrane technology to enable controlled airflow, actively pulling moisture and heat away from the body during intense aerobic activity.”
The harder you train, the harder the fabric works
More than external weather conditions, it is primarily the sweat trapped in clothing that most affects an athlete’s performance and causes discomfort. However, the unique combination of air permeability and Polartec’s exclusive nanofiber membrane ensures that Polartec® AirCore™ keeps users warm and dry during intense aerobic activities while preventing overheating – all while retaining its windproof and water-repellent properties.
“Polartec® AirCore™ is a highly breathable laminate that allows for continuous moisture exchange and uses the ambient air to ensure faster drying times, less moisture, and superior comfort even during maximum exertion. It represents a bold step forward in breathable weather protection,”
explains Karen Beattie, Director of Product Management at Polartec.
This state-of-the-art technology uses air to evaporate sweat from the inside out, thus maintaining a dry microclimate. Movement even promotes ventilation, ultimately wicking moisture away from the body. The harder you train, the harder the fabric works.
Best-in-Class Performance
The industry’s first air-permeable laminate, Polartec® AirCore™ has an air permeability of 0.4 to 1 CFM* to keep you dry from the inside while repelling water from the outside**. It also has an industry-leading Moisture Vapor Transmission Rate (MVTR) of over 25,000 g/m²/24 hours***. In addition, the lightweight material and excellent stretchability allow for unrestricted freedom of movement. This lets users experience air-driven, breathable dryness and comfort, and improved performance as a result.
Polartec® AirCore™ is made with a recycled face and back, which are combined with a non-PFAS membrane and layers. It will be part of Polartec’s weather protection category. For the launch, Polartec, part of Milliken & Company, is collaborating with selected brands. The fabric will be available in Castelli and Sportful’s autumn/winter 2025 cycling collections, which will be available from September 2025, whereas Montura will be the first brand partner in the Italian outdoor market to use Polartec® AirCore™ in its FW26 collection.
Key Polartec® AirCore™ Features:
- Air Permeable: Harnesses the power of air to keep you dry from the inside out
- Water Repellency: Minimum 4 spray rating (as is), per GB/T 4745-2012 (ISO 4920-2012, MOD)
- Functionally Windproof: Zero windchill
- High Breathability: Industry-leading MVTR* and air permeability** allow moisture and vapor to escape faster than traditional vapor breathable solutions
- Stretch for Comfort: Resilient stretch for a high range of motion during demanding activities
- Thoughtful Construction: Made with recycled materials and non-PFAS layers, membrane and DWR
* Air permeability (CFM) measured according to ASTM D737 at 125Pa.
** Water Repellent – Minimum 4 spray rating as is, per GB/T 4745-2012 (ISO 4920-2012, MOD).
*** MVTR measured according to JIS L1099, B1.
