Castelli Winter Gear with New Polartec AirCore – Review

By Sheri Rosenbaum

Castelli’s partnership with Polartec enabled it to incorporate AirCore into its Fall/Winter cycling gear, a genuinely revolutionary move. By utilizing the AirCore membrane in jackets, gloves, and shoe covers, cyclists can now enjoy lightweight, breathable, PFAS-free, and made from recycled materials that are windproof and water resistant.

Ramesh Kesh, Business Manager at Polartec, said:

“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 highly engineered nanofiber membrane technology to enable controlled airflow. This allows AirCore to actively maintain a dry microclimate during intense aerobic activity to keep the cyclist riding longer. In addition to setting a new paradigm in air-permeable and breathable, weather-resistant fabrics, it reflects our unwavering commitment to reducing the environmental impact of the textiles we create.”

Check out the Castelli podcast, where they discuss this new fabric.

Perfetto RoS 3 Winter Jacket

Castelli – Women’s; Men’s 

Price: $320 (on sale at the time of this review $240)

Sizes: XS to XL (women’s); XS to 2XL (men’s)

Fit: Tailored

Temperature Range: 4°C – 14°C / 39°F – 57°F

Weight: 244 g

Colors: Hibiscus, Black, Pool Blue, Mango Mojito (women’s); Black, Pool Blue, Rich Red, Mocha (men’s)

Materials: 150 g Polartec AirCore membrane

Vents: Two side zipper vents

Pockets: Three rear pockets

Zipper: Full front two-way zipper

Availability: Online and Retail

How Obtained: Company Sample

RBR Advertiser: No

Brave the Elements: Rain or Shine

Back in September, I sat in on a call with Steve Smith, Castelli’s Head of Cycling, MVC Group, and Ramesh Kesh, PhD, Polartec’s Business Manager, as they introduced Polartec’s new AirCore membrane.  The sample Perfetto RoS 3 jacket has been sitting in my “to test” pile ever since, waiting for cooler temps. Recently, Chicagoland temperatures dropped into the range sufficiently for testing (4°C – 14°C / 39°F – 57°F), and I headed out onto the trail to see how it faired. Spoiler alert: it performed great.

The naming convention for this jacket is: “Perfetto” means “perfect” in Italian, and “RoS” stands for “rain or shine.” This jacket protects you from rain with reflective taped shoulder seams, a higher collar, and a longer tail to keep spray from the tires off your bottom. The windproof design is perfect for those cold, blustery rides.

Since the jacket is not insulated, I wore a long-sleeve base layer on my test rides. The windproof fabric kept the cold north winds out and the warmth in. The side-zipper vents and two-way zippers allowed me to regulate my core temperature and avoid overheating.

Besides the longer rear hem, the Perfetto RoS 3 is perfect for rainy weather, including three rear pockets with drain holes. I’ll be honest, I’ve never seen pocket drain holes on a jacket, but it makes sense if you are riding in heavy rain.

About Polartec’s AirCore Membrane

A few weeks ago, I reviewed Sportful’s Fiandre 2 Winter Cycling Jacket, a sister company to Castelli, which uses Polartec’s new AirCore membrane. While the Castelli and Sportful jackets are very different, the technology used to create the fabric membrane is the same and they have exclusive rights to utilize AirCore technology in the cycling industry. Castelli uses a 150-gram version of the air-permeable membrane to provide breathability, windproofing, water resistance, and lightweight performance. In fact, the jacket weighs only 244 grams and rolls up easily to fit in a rear jersey pocket. 

Perfetto’s Fit

Typical of Italian gear, Castelli’s Perfetto RoS runs small. The jacket is tailored, making it a snug “close to the body” fit. However, the fabric is a super 4-way stretch that can be extended to over two times its original size, so movement is never restricted. 

Unfortunately, at launch time, the company could not send me a women’s version, so I ended up testing a men’s 2XL. While the sleeves were too long, I didn’t mind as the cuffs could be tucked in to keep cold air from blowing up the sleeves. 

Expresso 2 W Gloves (Women’s and Men’s versions)

Women’s version; Men’s version

Price: $110 (on sale at the time of this review $82.50)

Sizes: XS to 2XL (women’s); XS to 3XL (men’s)

Fit: Runs small

Temperature Range: 3°C – 10°C / 37°F – 50°F

Weight: 155 g

Colors: Black

Materials: Polartec AirCore on the back of the hand and PrimalLoft insulation

Keep Those Digits Warm

On October 21, 2025, Castelli introduced its Expresso gloves, which use Polartec AirCore technology. The fabric is used on the back of the hand, as the outer layer, to provide windproof, water-repellent, and breathable properties. The PrimalLoft insulation inner layer keeps your hands warm in temperatures between 37°F – 50°F (3°C – 10°C). 

On the glove’s back of the hand, Castelli has added a zipper to make it easy to put on and take off. At the wrist, there’s a tab to help pull the gloves on. The palm and fingers have silicon strips for a more secure grip of the handlebars. According to the press release, the gloves have touchscreen inserts on the fingertips. However, I couldn’t access my iPhone while wearing the gloves and had to remove them to take pictures or answer a call.

Sizing runs small for these gloves. I typically wear a women’s large in most brands, but had to request an XL. I highly recommend sizing up, but consult the sizing chart on the Castelli website before ordering. 

I tested the gloves in dry conditions down to the low 30s. My hands stayed warm until about 35 degrees, when the tips of my fingers started to get cold. Otherwise, they stayed toasty warm.

Bottom Line

Castelli’s partnership with Polartec to develop the revolutionary AirCore fabric has produced some excellent Fall/Winter cycling gear. I’m amazed at how lightweight can still mean warmth, windproofing, breathability, and functionality. 

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Sheri Rosenbaum regularly contributes articles and reviews products for RBR. She’s an avid recreational roadie who lives in the Chicago area and a major advocate for women’s cycling, serving on the board of directors and volunteering with the Dare2tri Paratriathlon Club. Click to read Sheri’s full bio or visit her web site sunflowersandpedals.com.